How to Replace the Fuel Return Line Opel Meriva A

Important: When working on the fuel system, it is essential that a high degree of cleanliness is maintained, as even the smallest particles of dirt can cause engine or fuel system malfunctions. Any fuel system connections which have been opened must be closed off with suitable sealing plugs available from the Opel Parts Catalogue. Sealing plugs are intended for single use only.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach negative clamp from ground terminal – Undo nut
3. 3. Remove engine cover
4. 4. Place collecting basin underneath
5. 5. Detach fuel return line (1) from injector • Release 4x retaining clamps (2) • Close off line and connections with cover caps

6. 6. Detach fuel return line (2) from accumulator • Detach from accumulator (3) – Release clamp • Detach fuel return line bracket (1) – Unscrew bolt • Close off line and connections with cover caps • Unclip 4x from toothed belt cover

7. 7. Raise vehicle all the way
8. 8. Remove fuel return line (1) • Release clamp • Unclip bracket

Install

9. 9. Install fuel return line • Fasten new clamp • Route fuel return line upwards • Clip into bracket
10. 10. Lower vehicle all the way
11. 11. Attach fuel return line to accumulator • Detach cover caps • Attach to accumulator – Fasten new clamp • Attach fuel return line bracket – Tighten bolt 7 Nm • Clip 4x into toothed belt cover
12. 12. Attach fuel return line to injector • Detach cover caps • Replace 4x seal rings • Fasten 4x retaining clamps
13. 13. Install engine cover.
14. 14. Connect battery • Attach negative clamp to ground terminal – Tighten nut
15. 15. Program volatile memory
16. 16. Close bonnet