Replacing Accumulator Opel Combo C

Important: Cleanliness is of the utmost importance when working with the fuel system. The smallest particle of dirt could cause engine malfunction or contaminate the fuel system. Open fuel systems must be sealed with a suitable plug from the Opel Parts catalogue (Cat. no. 45 06 154 / Part no. 9201697). Plugs are intended for one-time use only

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground clamp from ground terminal – Unscrew nut
3. 3. Remove air cleaner housing (1) • Disconnect wiring harness plug of hot film mass air flow meter (3) – Release in direction of arrow • Remove air intake hose (4) – Loosen clamp (5) • Remove bolt (2) • Disconnect wiring harness

4. 4. Remove engine cover (2) • Unscrew 2 bolts (1) • Detach oil filler port cover (3) • Unclip engine cover from bracket • Attach oil filler port cover

5. 5. Raise vehicle all the way
6. 6. Drain coolant • Place collecting basin underneath. • Open drain bolt
7. 7. Lower vehicle all the way
8. 8. Unscrew oil filter housing cover (1) with oil filter

9. 9. Detach fuse holder (1) from bracket
10. 10. Remove coolant compensation tank (2) • Detach 3 coolant hoses – Release 3x clamp • Remove bolt • Remove body-bound rivet • Unclip from upper front

11. 11. Remove engine management wiring harness • Disconnect 3 wiring harness plugs (arrows) – Engine control unit – 2 combination plugs • Detach ground cable from engine control unit – Unscrew nut • Expose wiring harness
12. 12. Remove air intake pipe • Detach from turbocharger – Release clamp • Unscrew 2 bolts • Detach engine vent hose from camshaft housing – Release clamp • Unclip wiring harness

13. 13. Remove engine control unit (1) • Disconnect wiring harness plug • Unscrew 2 bolts • Unscrew 2 nuts

14. 14. Remove engine control unit bracket (1) • Cut 3 cable ties • Unscrew 4 bolts

15. 15. Remove engine control unit bracket support (1) • Unscrew 2 bolts

16. 16. Disconnect engine wiring harness • Disconnect 4 wiring harness plugs for injectors (4) • Disconnect wiring harness plug of vacuum unit switchover valve (1) • Disconnect wiring harness plug of charge pressure sensor (2) • 2x unclip bracket • Separate cable tie • Disconnect 4 wiring harness plugs for glow plugs (3)

17. 17. Remove charge air pipe (1) • Unscrew and remove 3 stud bolts • Unscrew 3 bolts • Unscrew nut • Remove 2 gaskets

18. 18. Place collecting basin underneath.
19. 19. Detach fuel return line (1) • Unscrew banjo bolt and nut (2) • Release clamp

20. 20. Raise vehicle all the way
21. 21. Detach oil return hose (1) • Release 2x clamp

22. 22. Remove 2 blank holders • Unscrew 2 nuts (1) • Unscrew 4 bolts (2) • Unscrew 2 stud bolts (arrows) • Detach ground cable – Remove bolt • Disconnect 6 wiring harness plugs • Unclip vacuum line • Remove fuel line spacer (3)

Important. Be sure not to damage the high pressure line (2)

23. 23. Detach high pressure line (1) from high pressure pump at accumulator • Remove from bracket – Remove bolt • Remove union nut from accumulator using KM-812 and from high pressure pump using KM-6098 – Unscrew 2 union nuts • Seal connection of high pressure pump

24. 24. Detach 4 high pressure lines (1) from accumulator to injectors • Unscrew 8 union nuts (3) • Remove 2 high pressure line spacers (2)

Note. Seal off the high pressure lines and injectors

25. 25. Remove accumulator • Unscrew 2 bolts (arrows)

Note. Note differing bolts

Install

26. 26. Install accumulator • Screw in 2x bolt • Attach fuel return line – From high pressure pump to accumulator

Note. Note different lengths of bolts and spacer sleeves

27. 27. Install fuel return line • Tighten nuts • Tighten 2 bolts • Attach 4x fuel return line to injectors • Attach fuel return line to accumulator

Note. Note differing bolt lengths

28. 28. Attach 4 accumulator high pressure lines to injectors • Detach 8x closure caps • Hand-tighten 8x union nuts
29. 29. Fasten accumulator • Tighten 2x bolts 25 Nm
30. 30. Fasten accumulator high pressure lines to injectors • Tighten 8x union nuts with KM-812 and KM-6098 25 Nm Diameter Torque Version 1 6.00 mm 30 Nm Version 2 6.35 mm 25 Nm

Note. First tighten union nuts at the injectors and then at the accumulator

31. 31. Detach high pressure line from high pressure pump at accumulator • Remove 2 protective caps • Tighten 2 union nuts 25 Nm • Install in bracket – Tighten nuts
32. 32. Fit 2 blank holders • Tighten 2 stud bolts • Tighten 2 nuts • Tighten 4 bolts • Connect ground cable. – Tighten bolt • Connect 6x wiring harness plugs • Attach vacuum line
33. 33. Attach oil return line • Secure 2x clamp
34. 34. Lower vehicle all the way
35. 35. Install oil filter housing cover • Replace gaskets • Tighten cover 25 Nm
36. 36. Attach fuel return line • Attach to accumulator using new gaskets – Tighten banjo bolt • Attach to intake manifold – Tighten nuts
37. 37. Install charge air pipe • Replace 2 gaskets • Tighten nut 24.5 Nm • Tighten 3 bolts 24.5 Nm • Tighten 3 stud bolts 24.5 Nm
38. 38. Connect engine wiring harness • 2x clip in bracket • Fasten cable tie • Connect wiring harness plug of charge pressure sensor • Connect wiring harness plug of vacuum unit switchover valve • Connect 4 wiring harness plugs for glow plugs • Connect 4 injector wiring harness plugs
39. 39. Install engine control unit bracket support • Tighten 2 bolts
40. 40. Install engine control unit bracket • Tighten 4 bolts • Fasten 3 cable ties
41. 41. Install engine control unit • Tighten 2 bolts • Tighten 2 nuts • Connect wiring harness plug
42. 42. Install air intake manifold • Tighten 2 bolts • Attach engine vent hose to camshaft housing – Fasten clamp • Attach air intake pipe to turbocharger – Tighten clamp 3.5 Nm • Attach wiring harness
43. 43. Remove engine management wiring harness • Connect 3 wiring harness plugs • 3x clip in bracket • Connect ground cable to engine control unit – Tighten nuts
44. 44. Attach charge air hose to throttle valve connection • Tighten clamp 3.5 Nm
45. 45. Install coolant compensation tank • Clip in to upper front • Attach 3 coolant hoses – Secure 3x clamp • Tighten bolt • Install body-bound rivet
46. 46. Attach fuse holder to bracket
47. 47. Install air cleaner housing • Fasten cable harness • Tighten bolt • Install air intake hose – Tighten clamp 3.5 Nm • Connect wiring harness plug of mass air flow meter
48. 48. Install engine cover. • Detach oil filler port cover • Install engine cover. – Clip into bracket • Tighten 2 bolts • Attach oil filler port cover
49. 49. Top up coolant and adjust coolant level
50. 50. Connect battery • Attach ground clamp to ground terminal – Tighten nuts

Important. Wear protective goggles

51. 51. Carry out leak test on high pressure system • Carry out actuator test (fuel leak) • Inspect high pressure system for fuel leak

Note. Engine must be at operating temperature

52. 52. Program volatile memory
53. 53. Close bonnet