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. Open bonnet
- 2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
- 3. Remove engine cover
- 4. Place collecting basin underneath.
- 5. Detach fuel return line (1) from injector • Release 4x retaining clamps (2) • Seal off line and connections with sealing caps
- 6. Detach fuel return line (2) from accumulator • Detach from pressure chamber (3) – Release clamp • Detach fuel return line bracket (1) – Unscrew bolt • Seal off line and connections with sealing caps • Unclip 4x from toothed belt cover
- 7. Raise vehicle by its full height
- 8. Detach fuel return line (1) • Release clamp • Unclip bracket
Install
- 9. Install fuel return line • Fasten new clamp • Place fuel return line on top • Clip into bracket
- 10. Lower vehicle by its full height
- 11. Attach fuel return line to accumulator • Detach sealing caps • Attach to pressure chamber – Fasten new clamp • Attach fuel return line bracket – Tighten bolt 7 Nm • Clip 4x in toothed belt cover
- 12. Attach fuel return line to injector • Detach sealing caps • Replace 4x seal rings • Fasten 4x retaining clamps
- 13. Install engine cover
- 14. Connect battery • Attach ground connection to ground terminal – Tighten nut
- 15. Program volatile memories
- 16. Close bonnet