How to Check and Adjust the Injection Pump Timing Opel Frontera A

Injection Pump Timing, Check and Adjust

Due to the close internal tolerances of injection pump, the area around injection pump and injection pipes must be thoroughly cleaned.

All dirt, grease and other contaminants from area around injection pump and injection pipes.

Ribbed V - belt (3) - see corresponding operation.

Alternator (1) - see corresponding operation.

Lower alternator support bracket / idler pulley assembly (4) - two bolts and washers.

Harness connectors as necessary for access to injection pump.

Residual pressure held within injection pump by overflow valve (2) must be permitted to bleed off so that fuel timing mechanism can return to zero position.

If bleeding procedure is not done, subsequent fuel timing adjustment will not be accurate.

Bleed off residual pressure - loosen nut (3) and overflow valve (2) to loosen fuel return pipe (1); soak up excess fuel.

Injection pipes from injectors and injection pump - loosen pipe clips.

Seal ends of injection pipes and fuel injection pump to prevent ingress of foreign material.

Adapter KM - 226 - A (2) to injection pump.

Set dial gauge (1) to zero - ensure gauge tip is located against tip inside Adapter (2).

Slowly rotate crankshaft counterclockwise (viewed from front) until needle movement of gauge stops - do not rotate crankshaft after needle movement has stopped.

Set gauge to zero again.

Rotate crankshaft damper pulley clockwise and check gauge indicates 0.65 mm when top dead centre mark is aligned with timing pointer.

Final movement of injection pump must always be clockwise to set position before nuts are tightened. Do not rotate injection pump counterclockwise to set final position.

If limit of 0.65 mm is exceeded when injection pump is rotated clockwise, start timing procedure again.

Loosen nuts (arrowed) of injection pump just sufficient to rotate injection pump.

Rotate injection pump counterclockwise (viewed from front) until dial gauge indication is zero.

Injection pump nuts - 27 Nm / 20 lbf ft.

Head plug (1) with new copper washer (2).

Incorrectly positioned injection pipe clips will result in pipe breakage and fuel pulsing noises.

Injection pipes to injectors and injection pump - loosely install, place pipe clips in correct position, then tighten pipe nuts and clips.

Fuel return pipe (1), with new copper washers between injection pump, overflow valve (2), fuel return pipe and nut (3) - tighten overflow valve (2) and nut (3).

Injection pipe nuts - 23 Nm / 17 lbf ft.

Injection pipe clip screws - 18 Nm / 13 lbf ft.

High - pressure hose to connection (2) on power steering pump.

Harness connectors.

Alternator support bracket / idler pulley assembly (3) - two bolts and washers.

Alternator (1) - see corresponding operation.

Ribbed V - belt (2) - see corresponding operation.

Alternator support bracket / idler pulley assembly bolts - 83 Nm / 61 lbf ft.

Fill power steering fluid reservoir.

Bleed air from injection pump and fuel lines - see operation in group L.

Run engine until it is at normal operating temperature.

For fuel leaks.