Important: When working on the fuel system maintaining cleanliness is essential, otherwise the smallest particles of dirt may result in engine operating faults or faults in the fuel system. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.
Important: For the entire operation, it is essential to work in a clean environment.
- Dirt in the area from the pressure chamber to the fuel pressure control valve must be removed according to the prescribed procedure.
- Do not wear gloves.
Important: Observe the safety regulations! Refer to Safety regulations for the engine, fuel system and exhaust system
Remove
- 1. Open bonnet
- 2. Disconnect battery • Detach negative clamp from earth terminal – Undo nut
- 3. Remove pressure reservoir
- 4. Ensure that all connections from the pressure reservoir are sealed off after removal using suitable sealing plugs.
- 5. Screw the banjo bolt a small way into the threaded hole in the pressure relief valve
Note. A new banjo bolt is included in the delivery of new parts for the pressure relief valve.
- 6. Clean pressure reservoir (2) and pressure relief valve (1) • Use a suitable wire brush to clean away dirt in the threaded area (arrows) from the pressure reservoir to the pressure relief valve • Flush out dirt using a suitable brake cleaner • Remove brake cleaner and dirt using compressed air
- 7. Place collecting basin underneath. • The position of the fuel pressure sensor (1) must be outside of the vice • The connection of the fuel return line from the pressure relief valve (2) must point DOWNWARDS (arrow)
Important. Attach pressure reservoir as follows:
- 8. Attach pressure reservoir • Fasten the pressure reservoir in a suitable vice using clamping jaws
- 9. Carefully screw out the pressure relief valve (2)
Note. Right-hand thread.
- 10. Drain the pressure reservoir fully • Allow the remaining fuel to flow out of the pressure reservoir
Install
Important. If it is not possible to screw in the pressure relief valve to the stop (end of thread), the entire pressure reservoir assembly must be replaced.
- 11. Carefully screw in the pressure relief valve and hand-tighten
- 12. Tighten the pressure relief valve 30 Nm
Important. Re-clamp the pressure reservoir: The position of the fuel pressure sensor (2) must be outside of the vice The connection of the fuel return line from the pressure relief valve (1) must point UPWARDS (arrow)
- 13. Turn the pressure reservoir through 180° • Take the pressure reservoir out of the vice • Position the pressure relief valve towards the top • Fasten the pressure reservoir in a vice using clamping jaws
- 14. Apply markings • Mark the pressure relief valve at outside of hex head (1) using a suitable pen • Apply marking (2) on the pressure reservoir opposite to the marking of the pressure relief valve • Apply second marking (3) on the pressure reservoir 4 mm from marking (2)
Important. It must be possible to tighten the pressure relief valve until marking (1) is behind marking (3). If not possible, tighten the pressure relief valve to 190 Nm .
- 15. Tighten the pressure relief valve 172 Nm
- 16. Take the pressure reservoir out of the vice
- 17. Install accumulator
- 18. Connect battery • Attach earth clamp to earth terminal – Tighten nut
- 19. Program volatile memories
- 20. Carry out fuel leak test
- 21. Carry out visual check
- 22. Close bonnet