How to Replace the Injection Pump Gear (Simplex), Replace, Simplex Timing Chain Opel Vectra C

(Y 22 Dtr, with Air Conditioning, Rhd)

1. 1. Open bonnet
2. 2. Disconnect battery. • Detach ground cable
3. 3. Release right front wheel • Release 5x bolt
4. 4. Raise vehicle • Half height
5. 5. Disconnect right front wheel. • Unscrew 5x bolt
6. 6. Raise vehicle
7. 7. Remove lower engine cover (1) • Unscrew 10x bolt

8. 8. Detach ribbed V-belt • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow) • Remove ribbed V-belt

Note. Mark direction of rotation

9. 9. Remove ribbed V-belt tensioner • Unscrew 2x bolt (1), (2)

Important. Damper (3) may only be stored in upright position. Incorrectly stored dampers may be bled by repeated compression in installation position.

10. 10. Lower vehicle
11. 11. Remove upper engine cover • Unscrew 3x bolt

Important. Carefully pull upwards

12. 12. Remove air intake hose (2) • Release 3x clamp
13. 13. Remove air cleaner housing (3) • Disconnect wiring harness plug for hot film mass air flow meter (1) • Pull bracket for solenoid valve and atmospheric pressure sensor upwards • Unclip wiring harness • Detach intake hose • Remove pollen filter housing (3)

14. 14. Disconnect wiring harness plug for air conditioning pressure switch
15. 15. Detach upper charge air pipe (1) • Release 2x clamp • Unscrew 2x bolt (2)

16. 16. Remove brake servo vacuum line • Release and unclip brake servo vacuum line
17. 17. Detach wiring trough (1) • Unscrew 2x bolt • Unclip wiring harness • Lay wiring trough aside.
18. 18. Detach coolant line (2) • Unscrew 2x bolt

19. 19. Disconnect wiring harness plug for intake pipe pressure sensor (1)

20. 20. Detach wiring harness bracket for engine management • Unscrew 2x bolt (arrows)

21. 21. Remove vacuum pump (2) • Detach vacuum hose • Unscrew 4x bolt (1) • Remove gasket (3)

22. 22. Detach 2x fuel line, vacuum line • From cylinder head cover • Set components to one side
23. 23. Disconnect cylinder head cover. • Unscrew 8x bolt • Remove gasket.
24. 24. Release timing case cover (1) • Unscrew 4x upper bolt
25. 25. Raise vehicle
26. 26. Remove timing case cover (1) • Unscrew 2x lower bolt

Important. Carefully separate timing case cover from timing case using wide spatula (2) Do not lever off timing case cover or use force to separate it from timing case, as permanent deformation results in leakage.

27. 27. Remove crankshaft pulse pickup (1) • Unclip wiring harness • Remove bolt

28. 28. Remove Duplex chain tensioner (3) • Remove bolt (1), seal ring (2), chain tensioner (3)

Note. Note installation position.

29. 29. Lower vehicle • Half height
30. 30. Preselect 1st cylinder TDC of combustion stroke

Note. Turn crankshaft uniformly in direction of engine rotation. Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

31. 31. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

32. 32. Lower vehicle
33. 33. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

34. 34. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

35. 35. Remove KM-927 , KM-932
36. 36. Remove Simplex chain tensioner (2). • Remove bolt, seal ring, chain tensioner

Note. Note installation position.

37. 37. Remove guide rail for Simplex timing chain (3) • Remove 2x bolt (1) • Remove guide rail upwards

Important. Heat bolts intensively with hot air blower and unscrew. Use suitable heat shielding

Note. Note installation position.

38. 38. Remove camshaft sprocket • Remove bolt

Note. Counterhold camshaft at hexagonal section. Attach Simplex timing chain at a suitable place.

39. 39. Remove Simplex injection pump gear • Unscrew 4x bolt (1) • Lower Simplex timing chain downwards • Remove Simplex injection pump gear at side • Remove Simplex timing chain upwards

Important. Arrow (2) on Simplex fuel injection pump gear must align with recess in fuel injection pump flange and retaining bore (3) in fuel injection pump.

40. 40. Install Simplex injection pump gear • Use KM-927 (4)

Note. Insert Simplex timing chain with Simplex fuel injection pump gear and hand-tighten Simplex fuel injection pump gear with fastening bolts (1). Ensure bolt strength 10.9 of the fastening bolts

41. 41. Raise vehicle
42. 42. Install Duplex chain tensioner (3) • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position. Closed side of chain tensioner (3) must point to tension rail.

43. 43. Lower vehicle
44. 44. Tighten Simplex injection pump gear • Remove KM-927 • Tighten 4x bolt – Tightening torque 28 Nm • Use KM-927
45. 45. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

46. 46. Remove KM-932 , KM-927
47. 47. Insert camshaft sprocket • Replace bolt • Position Simplex timing chain • Screw in bolt

Important. Ensure that camshaft sprocket is seated squarely on camshaft – camshaft sprocket must sit flat against camshaft.

48. 48. Install guide rail for Simplex timing chain (1) • Replace 2x bolt (2) • Tighten 2x bolt – Tightening torque 8 Nm

Important. Note installation position of guide rail

49. 49. Attach KM-933 (4) • Insert carrier (1) • Screw in 2x bolt

Note. Position upright in camshaft pulley

Important. It must be possible to remove and install KM-927 under suction. If this is not possible, the pressure on the adapter plate must be slightly reduced using the adjustment screw (3).

50. 50. Adjust KM-933 (4)

Note. Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

51. 51. Secure camshaft sprocket • Tighten bolt – Tightening torque 90 Nm + 60° + 30°
52. 52. Install Simplex chain tensioner (3) • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position. Close side of chain tensioner (3) must point to tension rail

53. 53. Raise vehicle • Half height
54. 54. Remove KM-929
55. 55. Turn crankshaft

Note. Turn crankshaft slowly and uniformly two rotations (720°) in direction of engine rotation until just before 1st cylinder TDC of combustion stroke Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

56. 56. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

57. 57. Lower vehicle
58. 58. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

59. 59. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

60. 60. Remove KM-932 , KM-927
61. 61. Raise vehicle
62. 62. Remove KM-929
63. 63. Install crankshaft pulse pick-up • Replace seal ring • Tighten bolt – Tightening torque 8 Nm • Route cable

Important. The application of silicone sealing compound (grey), installation of timing case cover and tightening to torque must be performed within 10 minutes.

64. 64. Install timing case cover • Screw in 3x bolt at bottom

Note. Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound (grey) to timing case cover.

65. 65. Lower vehicle
66. 66. Secure timing case cover • Tighten 6x bolt – Tightening torque 6 Nm
67. 67. Attach cylinder head cover • Replace gasket • Tighten 8x bolt – Tightening torque 8 Nm

Note. Gasket (2) must be inserted in gap (1) between cylinder head cover and sleeve. Apply wetting agent (colourless) to sealing surfaces (arrows).

68. 68. Attach 2x fuel line, vacuum line • To cylinder head cover
69. 69. Install vacuum pump • Replace gasket • Connect vacuum hose. • Tighten 4x bolt – Tightening torque 8 Nm
70. 70. Attach wiring harness bracket for engine management • Tighten 2x bolt
71. 71. Connect wiring harness plug for intake pipe pressure sensor
72. 72. Attach coolant line • Tighten 2x bolt
73. 73. Attach wiring trough • Attach wiring harness • Tighten 2x bolt
74. 74. Attach brake servo vacuum line • Clip in and lock brake servo vacuum line
75. 75. Connect wiring harness plug for air conditioning pressure switch
76. 76. Install air cleaner housing • Clip in bracket for solenoid valve and atmospheric pressure sensor • Attach wiring harness • Install suction hose • Connect wiring harness plug to hot film mass air flow meter
77. 77. Install air intake hose. • Secure 3x clamp – Tightening torque 3,5 Nm
78. 78. Attach upper charge air pipe • Secure 2x clamp – Tightening torque 3,5 Nm • Tighten 2x bolt – Tightening torque 3 Nm
79. 79. Install upper engine cover • Clip in upper engine cover • Tighten 3x bolt
80. 80. Raise vehicle
81. 81. Install ribbed V-belt tensioner • Tighten 2x bolt – Tightening torque (M8) 20 Nm – Tightening torque (M10) 42 Nm
82. 82. Attach ribbed V-belt • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)

Note. Note running direction

83. 83. Install lower engine cover • Tighten 10x bolt
84. 84. Lower vehicle • Half height
85. 85. Attach right front wheel • Screw in 5x bolt
86. 86. Lower vehicle
87. 87. Secure right front wheel • Tighten 5x bolt – Tightening torque 110 Nm
88. 88. Connect battery. • Connect ground cable.
89. 89. Program volatile memories
90. 90. Close bonnet