Replacing Accumulator 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. Detach fuel return line (2) • Unscrew banjo bolt (3) • Remove holder – Unscrew bolt (1)

5. 5. Remove high pressure line (3) between high pressure pump and accumulator • Remove from bracket – Unscrew bolt (4) • Disconnect wiring harness plug for sheathed glow plug (2) of cylinder 1 • Unscrew 2x union nuts (1) • Close off connections with cover caps

Note. Release plug with EN-48558 and pull off manually

6. 6. Remove 4x high pressure lines between accumulator and injectors • Unscrew 8x union nuts (1) • Close off the accumulator connections with suitable sealing plugs • Close off the injector connections with EN-48559

7. 7. Remove accumulator (1) • Disconnect wiring harness plug (arrow) • Unscrew 2x bolts (2)

Install

8. 8. Install pressure reservoir • Tighten 2x bolt 25 Nm • Connect wiring harness plug
9. 9. Install 4x high-pressure lines, accumulator to injector • Detach 4x cover caps • Detach 4x EN-48559 from injectors • Tighten 8x union nuts with MKM-6600-308 and KM-6600-1 25 Nm

Note. Tighten union nuts on injectors first, then on accumulator

10. 10. Attach high pressure line to accumulator • Detach cover caps • Tighten union nut with MKM-6600-207 and KM-6600-1 25 Nm • Install bracket – Tighten bolt • Connect wiring harness plug of cylinder 1 sheathed glow plug
11. 11. Attach fuel return line • Tighten banjo bolt 10 Nm • Connect holder – Tighten bolt
12. 12. Raise vehicle all the way
13. 13. Fasten high pressure line to high pressure pump • Tighten union nut with MKM-6600-12 and MKM-6600-308 25 Nm
14. 14. Lower vehicle all the way
15. 15. Install engine cover.
16. 16. Connect battery • Attach negative clamp to ground terminal – Tighten nut

Important. Wear protective goggles

17. 17. Carry out a leak test on the high pressure system • Carry out actuator test (fuel leak) • Visual inspection of high pressure system for fuel leak

Note. Engine must be at operating temperature

18. 18. Programming with Tech 2
19. 19. Program volatile memory
20. 20. Close bonnet