Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.
Remove
- 1. Open bonnet
- 2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
- 3. Raise vehicle by its full height
- 4. Remove lower engine compartment cover and/or right-hand engine splash guard
- 5. Place collecting basin underneath.
- 6. Lower vehicle by its full height
- 7. Remove engine cover
- 8. Remove air cleaner housing
- 9. Detach fuel return damping case (2) • Remove fuel return line (4) with KM-796-A • Detach fuel hose (1) – Release clamp • Disconnect oil leak line (3) • Unscrew 2x bolts (arrows)
- 10. Disconnect high-pressure pump wiring harness plug (1)
Important. After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1)
- 11. Remove high pressure line (4) from high pressure pump to pressure chamber • Unscrew 2x union nuts
Note. Seal pressure chamber, high-pressure pump and high-pressure line with sealing cap from kit (part number 9 20 16 97)
- 12. Detach high-pressure pump fuel supply line (2) • Release clamp
- 13. Remove upper toothed belt cover • Unscrew 5x bolts (1) with EN-47631 • Unscrew 2x bolts (2) • Unclip wiring harness
Important. The retaining bolts must be 40 mm long. Threads may be no more than 10 mm. Otherwise the sliding of the high pressure pump drive gear on the bolts cannot be guaranteed.
- 14. Adjust high-pressure pump • Turn the steering wheel to the right • Rotate the engine at the crankshaft in the direction of engine rotation until the retaining bolts (1) M6x40 in the high-pressure pump bracket can be turned
- 15. Release high-pressure pump drive gear • Unscrew nut (2)
- 16. Slacken high pressure pump • Unscrew 3x nuts (1)
Note. Place cloths under the high-pressure pump to prevent the loss of nuts or wedges
Important. Make absolutely certain that the feather key is also removed.
- 17. Remove high pressure pump • Using EN-46790 , press out the assembly from the high-pressure pump gear – Counterhold with open-ended wrench (2)
Install
Important. The spring key must be attached when the high-pressure pump is replaced. The shaft of the high-pressure pump must be set so that the spring key can be inserted in the designated opening of the high-pressure pump drive gear.
Important. Make absolutely certain that the spring key does not fall out during installation.
- 18. Install high pressure pump • Tighten 3x new nut 25 Nm
Important. Slide the high-pressure pump drive gear onto the high-pressure pump shaft by hand
- 19. Fasten the high-pressure pump drive gear • Tighten nut 50 Nm
Note. Use new nuts
- 20. Unscrew the retaining bolt from the high-pressure pump drive gear
Important. Check the high-pressure pump drive gear for fractures and cracks
- 21. Install upper toothed belt cover • Tighten 5x bolts with EN-47631 • Tighten 2x bolts • Attach wiring harness
- 22. Install high-pressure line of high-pressure pump to pressure chamber • Detach sealing caps • Tighten 2x retaining nut – (M12) 25 Nm – (M14) 23 Nm
- 23. Connect high-pressure pump wiring harness plugs
- 24. Attach high-pressure pump fuel supply line • Fasten clamp
- 25. Attach fuel return damping case • Tighten 2x bolts • Attach fuel return line – Connect quick release fitting • Attach fuel hose – Fasten clamp • Attach oil leak line
Note. Must engage audibly
- 26. Install air cleaner housing
- 27. Install engine cover
- 28. Raise vehicle by its full height
- 29. Attach water drain hose of air cleaner housing
- 30. Install lower engine cover and right engine splash guard
- 31. Lower vehicle by its full height
- 32. Connect battery • Attach ground connection to ground terminal – Tighten nut
- 33. Program volatile memories
- 34. Close bonnet
1
) Protective caps are available from the Opel parts catalogue under catalogue number 45 06 154 / part number: 9201697