Replace High Pressure Pump Opel Meriva A

Warning: When working on the Common Rail System, please wait for one minute after switching the engine off. The system relieves the pressure automatically.

Important: When working with fuel systems, cleanliness must be ensured at all times since even the smallest dirt particles can lead to disruptions of engine operation or in the fuel system. Plug open fuel fittings with suitable sealing plugs. 1) Sealing plugs are intended for single use only.

Remove

1. 1. Remove air intake manifold • Unscrew 2x bolt • Unclip 3x wiring harnesses • Detach engine vent hose – Disconnect quick-release fitting • Detach from air intake manifold – Release clamp • Detach from turbocharger – Release clamp
2. 2. Remove high pressure line (1) • Unscrew 2 union nuts

3. 3. Detach 2x fuel lines (1) • Release 2x clamp

4. 4. Remove vacuum pump
5. 5. Remove high pressure pump (1) • Unscrew 3x bolt

6. 6. Install high pressure pump • Renew seal ring • Tighten 3x bolt 15 Nm

Note. Carrier disk (1) must engage in groove (2) in camshaft

7. 7. Install vacuum pump
8. 8. Install high pressure line • Tighten union nut M12 24 Nm • Tighten union nuts (M14) 28 Nm

Note. Use new high pressure line

9. 9. Attach 2x fuel lines • Attach 2x clamps
10. 10. Install air intake manifold • Attach to turbocharger – Tighten clamp 3.5 Nm • Attach to air intake manifold – Tighten clamp 3.5 Nm • Tighten 2 bolts • Attach engine vent hose – Fasten clamp • Clip in 3x wiring harnesses

1

) Protective caps can be ordered from the parts catalogue