Replace Pressure Reservoir Opel Corsa D

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.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach negative clamp from earth terminal – Undo nut
3. 3. Remove engine cover

4. 4. Detach wiring harness for engine management (1) • Disconnect 4x wiring harness plugs for injector (2) • Remove wiring trough – Unscrew 3 bolts (arrows)

5. 5. Detach glow plug wiring harness (1) • Disconnect 4x glow plug plug (4) • Disconnect pressure chamber wiring harness plug (3) • Unscrew bolt (2) • Set wiring harness to one side

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

6. 6. Detach fuel return line (2) • Unscrew banjo bolt (3) • Remove bracket – Unscrew bolt (1)

7. 7. Remove high-pressure line (1) from high-pressure pump to pressure chamber • Unscrew 2x union nut (2) • Seal off connections with sealing caps
8. 8. Detach 4x high-pressure lines from pressure chamber to injector • Unscrew 8x lock nut (1) • Seal off connections on pressure chamber with suitable sealing plugs • Seal off connections on injectors with EN-48559

9. 9. Remove pressure reservoir (1) • Remove 2x bracket (arrows) – Unscrew 2x nut (3) • Unscrew 2x bolts (2)

Install

10. 10. Install accumulator • Insert 2x bracket – Tighten 2x nuts • Tighten 2x bolt 25 Nm
11. 11. Install 4x accumulator high-pressure lines to injector • Detach 8x sealing plug • 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.

12. 12. Attach high-pressure line to pressure chamber • Detach closure caps • Tighten union nut with MKM-6600-207 in conjunction with KM-6600-1 25 Nm – Tighten bolt
13. 13. Attach fuel return line • Tighten banjo bolt 10 Nm • Attach bracket – Tighten bolt
14. 14. Fasten high-pressure line to high-pressure pump • Tighten union nut with MKM-6600-12 and MKM-6600-308 25 Nm
15. 15. Attach glow plug wiring harness • Connect 4x glow plug plug • Connect accumulator wiring harness plug • Tighten bolts
16. 16. Attach wiring harness for engine management • Route wiring harness – Connect 4x injector wiring harness plug – Attach wiring harness • Attach wiring trough – Tighten 3x bolts
17. 17. Install engine cover
18. 18. Connect battery • Attach earth clamp to earth terminal – Tighten nut
19. 19. Programming with the Tech 2
20. 20. Program volatile memories
21. 21. Close bonnet