Valve Timing Check Opel Agila B

Remove

1. 1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. 2. Raise vehicle
3. 3. Release 2x protective panelling from front panelling • Remove 4x clip (1)

4. 4. Lower vehicle
5. 5. Remove cover (1) from engine • Remove 4x bolt

6. 6. Remove engine cover bracket and camshaft cover insulation (1) from engine • Remove 2x bolt (2)

7. 7. Remove intercooler outlet pipe (2) from engine • Move camshaft cover insulation to one side • Release clip (1) • Remove 5x bolt

8. 8. Remove high pressure fuel pipe (2) from high pressure pump and fuel rail • Place collecting basin underneath. • Release 2x pipe union (1) • Install 4x new blanking plug
9. 9. Remove 4x injector pipe (3) from 4x fuel injector and fuel rail • Release 8x union • Install 16x new blanking plug

10. 10. Disconnect 4x harness connector (1) from 4x fuel injector
11. 11. Disconnect 4x glow plug connector (3)
12. 12. Disconnect harness connector (2) from camshaft sensor

13. 13. Disconnect harness connector from fuel pressure regulator (1)

14. 14. Disconnect harness connector (2) from fuel pressure sensor (1)

15. 15. Release engine wiring harness (1) from camshaft cover • Remove 3x bolt (2)

16. 16. Remove fuel rail (2) from fuel rail mounting bracket • Remove 3x bolt (1), then release fuel return hose from fuel return pipe • Release clip
17. 17. Remove engine cover bracket from fuel rail bracket • Remove, bolt
18. 18. Remove fuel rail mounting bracket (3) from engine • Remove 3x bolt

19. 19. Remove 2x blanking plug from camshaft housing

20. 20. Clean 4x threads • From closure bolts, camshaft housing
21. 21. Install 2x Camshaft Positioning Tool EN-46781 (1) in camshaft housing • Ensure correct installation position

Note. Fixing for Camshaft Positioning Tool must be installed in the horizontal position. To do this, apply marking to Camshaft Positioning Tool as an aid (arrow).

22. 22. Lock camshafts • Turn crankshaft carefully in direction of engine rotation by the bolt on the torsional vibration damper flange until Camshaft Positioning Tool EN-46781 engages audibly in both camshafts

Note. Ensure that the Camshaft Positioning Tool does not twist.

23. 23. Raise vehicle by its full height
24. 24. Lock crankshaft • Insert EN-46785 (1) through bore in transmission housing • Turn crankshaft carefully at bolt for torsional vibration damper flange until EN-46785 engages in flywheel

Note. If it is not possible to fix in position, the timing must be adjusted – see operation “Valve Timing Adjust” .

Install

25. 25. Remove EN-46785
26. 26. Lower vehicle by its full height
27. 27. Remove 2x Camshaft Positioning Tool EN-46781
28. 28. Install 2x blanking plug 15 Nm to camshaft housing • Apply suitable locking compound

29. 29. Install fuel rail mounting bracket (3) to engine • Install 3x bolt 28 Nm
30. 30. Install engine cover bracket to fuel rail bracket • Install bolt
31. 31. Install fuel rail (2) to fuel rail mounting bracket • Install 3x bolt (1), do not tighten at this stage

32. 32. Install 4x new high pressure pipe (4) to fuel rail and 4x fuel injector • Remove 16x blanking plug • Install 8x union, do not tighten at this stage
33. 33. Install new high pressure pipe to common rail and high pressure fuel pump • Remove 4x blanking plug • Install 2x union, do not tighten at this stage
34. 34. Secure fuel rail (1) to cylinder head • Secure 3x bolt (2) 25 Nm
35. 35. Secure 4x high pressure pipe union to 4x fuel injector • Secure 4x pipe union 27 Nm
36. 36. Secure high pressure pipe union to high pressure pump • Secure pipe union 27 Nm
37. 37. Secure 2x high pressure pipe union (3) to fuel rail • Secure 2x union 29 Nm
38. 38. Secure 3x high pressure pipe union to fuel rail • Secure 3x union 32 Nm

39. 39. Secure engine wiring harness (1) to camshaft cover • Install 3x bolt (2) 11 Nm

40. 40. Connect harness connector (2) to fuel pressure sensor (1)

41. 41. Connect harness connector to fuel pressure regulator (1)

42. 42. Connect 4x harness connector (1) to 4x fuel injector
43. 43. Connect 4x glow plug connector (3) to 4x glow plug
44. 44. Connect harness connector (3) to camshaft sensor

45. 45. Install intercooler outlet pipe (2) to engine • Secure clip (1) • Install 5x bolt

46. 46. Install engine cover bracket and cylinder head cover insulation (1) to engine • Install 2x bolt (2) 11 Nm

47. 47. Install cover (1) to engine • Install 4x bolt 8 Nm

48. 48. Secure 2x protective panelling to front panelling • Install 4x clip (1)

49. 49. Lower vehicle