[Basilio]

Ootasin üle kahe nädala pikki E-Torx padruneid, ilma milleta KSP-d lahti ei saa. Lammutamise käigus avastan järjest puuduvaid tööriistu, mida tuleb siis hankida. Pärnus on aga valik väike või olematu. Mõnes poes pole E-Torxist kuuldudki jne. Seni remont seisis ja tegelesin muude töödega, üks kiirem ja hädalisem kui teine. Nüüd vajalikud võtmed olemas ja katsun nädalavahetusel muude kohustuste kõrval ka selle asjaga edasi tegeleda.
Et jutt kuivaks ei jääks, siis riputan üles paar joonist. Esimene neist sisaldab vajalikku infot märkide kokku ajamiseks Opeli diislil. Lisaks õpetus. Äkki läheb veel mõnel tarvis. Tuubiku õpetused on väääga pealiskaudsed ja tähtsamatest nüanssidest libisetakse sujuvalt üle.
       
Special tools
·        Camshaft locking tool – No.KM-932.
·        Camshaft sprocket holding tool – No.KM-933.
·        Crankshaft locking pin – No.KM-929.
·        Crankshaft pulley holding tool – No.KM-930 or KM-977-1/956-1.
·        Injection pump locking pin – No.KM-927.
General precautions
·        Disconnect battery earth lead.
·        Remove glow plugs to ease turning engine.
·        Turn engine in normal direction of rotation (unless otherwise stated).
·        DO NOT use special tools listed above to lock engine when slackening sprocket bolts.
·        Observe tightening torques.
·        Mark position of crankshaft position (CKP) sensor before removal.
·        Do NOT turn crankshaft via camshaft or other sprockets.
·        Do NOT turn crankshaft or camshaft with timing chain removed.
·        Check diesel injection pump timing after resetting valve timing.

• Turn crankshaft until just before crankshaft pulley timing marks aligned.
  
• Ensure No.1 cylinder camshaft lobes are facing upwards [1] .
  
• Remove crankshaft position (CKP) sensor [2] .
  
• Slowly turn crankshaft clockwise until locking pin can be inserted in crankshaft [3] . Tool No.KM-929.
  
• Engine at TDC on No.1 cylinder.
  
• Ensure crankshaft pulley timing marks aligned [4] .
  
• Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
  
• Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
  
• Ensure peg locates in camshaft [7] .
  
• Injection pump timing adjustment:
  • • Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
      
    • Remove timing chain tensioners [8] & [9] . Note installation positions.
      
    • Remove camshaft sprocket bolt [10] . Fit new bolt.
      
    • Tighten bolt until camshaft sprocket turns freely but does not tilt.
      
    • Remove injection pump sprocket bolts [11] . Fit new bolts (bolt classification – 10.9).
      

·        NOTE: Injection pump sprocket may have 5 bolts.
§ Turn injection pump sprocket until arrow and hole aligned [12] .
§ Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
§ Install lower timing chain tensioner [9] . Tightening torque: 60 Nm.
§ Remove injection pump locking pin [5] .
§ Tighten injection pump sprocket bolts [11] . Tightening torque: 28 Nm.
§ Adjust valve timing.
·        Valve timing procedures:
§ Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
§ Ensure injection pump locking pin inserted [5] . Tool No.KM-927.
§ Ensure upper timing chain tensioner removed [8] .
§ Ensure new camshaft sprocket bolt tightened until camshaft sprocket turns freely but does not tilt.
§ Ensure arrow on injection pump sprocket and hole aligned [12] .
§ Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
§ Ensure peg locates in camshaft [7] .
§ Install camshaft sprocket holding tool [13] . Tool No.KM-933.
§ Apply slight anti-clockwise pressure on camshaft sprocket using lever [14] . Retain lever in position using locking bolt [15] .
§ Ensure injection pump locking pin can be removed and inserted easily [5] .
§ Tighten camshaft sprocket bolt [10] . Tightening torque: 90 Nm + 60° + 30°.
§ Install upper timing chain tensioner [8] . Tightening torque: 60 Nm.
§ Turn crankshaft 2 turns clockwise to TDC on No.1 cylinder.
§ Install special tools and check valve timing and injection pump timing.
·        Timing chain tensioner with release pin [16] :
§ After installation, release timing chain tensioner by pressing pin until click is heard.
§ Ensure pin can be pushed in fully with thumb pressure and returns to original position.
NOTE: Engine oil pressure will prevent release pin from being pushed in.
·        Camshaft rotation can be prevented using spanner at position shown [17] .
·        Auxiliary drive belt tensioner:
§ Store in upright position.
§ Bleed incorrectly stored tensioner by repeated compression in upright position.
NOTE: Crankshaft pulley central bolt MUST only be used once.