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Contents Wiring diagrams Section: Fuel Injection Systems All sections

How to Replace the Pressure Chamber Opel Astra H

Fuel Injection Systems 4 illustrations ~439 words

Important: When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery • Detach negative connection from ground terminal – Slacken nut
  3. 3. Remove engine cover
  4. 4. Detach fuel return line (2) • Unscrew banjo bolt (3) • Detach bracket – Unscrew bolt (1)
  1. 5. Remove high-pressure line (3) from high pressure pump to pressure chamber • Remove from bracket – Unscrew bolt (4) • Disconnect wiring harness plug, sheathed glow plug (2) of cylinder 1 • Unscrew 2x union nuts (1) • Seal off connections with sealing caps

Note. Release plug with EN-48558 and pull off by hand

  1. 6. Detach 4x high-pressure lines from pressure chamber to injector • Unscrew 8x union nut (1) • Seal off connections on pressure chamber with suitable sealing plugs • Seal off connections on injectors with EN-48559
  1. 7. Remove accumulator (1) • Disconnect wiring harness plug (arrow) • Unscrew 2x bolts (2)

Install

  1. 8. Install accumulator • Screw in 2x bolts • Fix wiring harness plug
  2. 9. Install 4x high-pressure lines from pressure chamber to injectors • Detach 8x sealing caps • Tighten 8x union nuts hand-tight
  3. 10. Fasten pressure chamber • Tighten 2x bolt 25 Nm
  4. 11. Attach 4x high-pressure lines from pressure chamber to injector • Tighten 8x union nuts with MKM-6600-308 in conjunction with KM-6600-1 25 Nm

Note. Tighten union nuts first at injectors, then at pressure chamber

  1. 12. Attach high-pressure line to pressure chamber • Detach sealing caps • Tighten union nut with MKM-6600-207 in conjunction with KM-6600-1 25 Nm • Install bracket – Tighten bolt • Connect wiring harness plug, sheathed glow plug of cylinder 1
  2. 13. Attach fuel return line • Tighten banjo bolt 10 Nm • Attach bracket – Tighten bolt
  3. 14. Raise vehicle by its full height
  4. 15. Fasten high-pressure line to high-pressure pump • Tighten union nut with MKM-6600-12 and MKM-6600-308 25 Nm
  5. 16. Lower vehicle by its full height
  6. 17. Connect battery • Attach negative connection to ground terminal – Tighten nut

Important. Wear protective goggles

  1. 18. Carry out leak test on high pressure system • Carry out actuator test (fuel leak) • Visual inspection of high pressure system for fuel leak

Note. Engine must be at operating temperature

  1. 19. Install engine cover
  2. 20. Program volatile memories
  3. 21. Programming the rail pressure sensor with Tech 2
  4. 22. Close bonnet

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