How to Replace the High Pressure Pump Opel Vectra C

Remove

1. 1. Open bonnet
2. 2. Disconnect battery. • Detach ground clamp from ground terminal – Remove nut
3. 3. Remove engine cover (1) • Unclip engine vent hose from bracket (2) • Unscrew 2x bolt (4) • Unscrew oil filler cap (5) • Remove engine cover • Screw in oil filler cap

Note. Replace any rubber retainers (3) that may have been detached from the engine cover

4. 4. Raise vehicle by its entire height
5. 5. Remove lower engine compartment cover and right-hand engine splash protection if necessary
6. 6. Attach KM-6313 (1) • Place KM-6313 on left on front axle body (arrows, Fig. I) • Attach both right holders on the front axle body (arrows, Illus. II). • Tighten 2x bolt

Note. Guide pin must be seated in bore in front axle body.

Note. Guide pin must be seated in bore in front axle body (arrow, Illus. III).

7. 7. Attach KM-6313-100 (2) • Remove bolt of compressor support • Attach adapter (1) – Screw in bolt
8. 8. Adjust 3x support • Transmission side • Engine Timing Side

Note. Turn spindles (3) until the mounts are positioned at the guide journals free of play.

Note. Insert journal of support in angle bracket, tighten nut.

9. 9. Lower vehicle by its entire height
10. 10. Place collecting basin underneath.
11. 11. Detach damping case, fuel return (2) • Unclip wiring harness from bracket • Separate wiring harness plug for high pressure pump • Unclip 2x fuel line from bulkhead bracket • Unclip fuel return line from bracket • Remove fuel return line (4) using KM-796-A • Detach fuel hose (1) – Release clamp • Separate oil leak line (3) • Unscrew 2x bolt (arrows)

12. 12. Detach fuel supply line (1) high pressure pump • Release clamp
13. 13. Separate wiring harness plug for high pressure pump (2)

14. 14. Remove high pressure line (1), high pressure pump to pressure reservoir • Unscrew 2x union nut

Important. Counterhold with open-ended wrench when releasing the lock nut on the high pressure diesel fuel pump.

Note. Seal pressure accumulator, high pressure pump and high pressure line with sealing caps from kit (part number 9201697)

15. 15. Remove right engine damping block • Release engine bracket adapter – Unscrew 3x bolt (1) • Loosen engine damping block – Unscrew 2x bolt – Unscrew nut (2)

16. 16. Remove upper toothed belt cover • Unscrew 4x bolts (1) with EN-47631 • Unscrew 2x bolt (2) • Unclip wiring harness

17. 17. Detach wiring harness diesel electronics from intake manifold • Unscrew 2x bolt • Unclip from bracket • Disconnect wiring harness plug from injector 1
18. 18. Detach wiring harness bracket • Unscrew 2x bolt

Important. The bolt must be 40 mm long, the thread length may only be 10 mm, otherwise the slipping of the high pressure pump drive wheel on the bolt cannot be guaranteed.

19. 19. Adjust high pressure pump. • Turn steering wheel fully to right • Turn engine in direction of engine rotation at crankshaft until the fixing bolts (1) M6x40 can be screwed into the high pressure pump bracket.
20. 20. Release high pressure pump drive wheel • Unscrew nut

21. 21. Release high pressure pump • Unscrew 3x nut (1)

Note. Place cloth below high pressure pump to avoid losing the nuts.

Important. It is essential to ensure that the shaft of the high pressure pump does not twist.

22. 22. Remove high pressure pump • Press completely off high pressure pump using EN-46790

Install

23. 23. Install high pressure pump • Tighten 3x new nuts 25 Nm

Important. Manually push high pressure pump drive wheel onto high pressure pump shaft.

24. 24. Attach high pressure pump drive wheel • Tighten nut 50 Nm
25. 25. Unscrew fixing bolts from high pressure pump drive wheel
26. 26. Attach wiring harness bracket • Tighten 2x bolt
27. 27. Attach wiring harness diesel electronics to intake manifold • Connect wiring harness plug to injector 1 • Clip into bracket • Tighten 2x bolt

Important. Check high pressure pump wheel for breakage and cracks

28. 28. Install upper toothed belt cover • Tighten 4x bolts with EN-47631 • Tighten 2x bolt • Attach wiring harness
29. 29. Install right engine damping block • Fasten engine damping block – Tighten 2x bolt 55 Nm – Tighten nuts 55 Nm • Fasten engine bracket adapter – Tighten 3x bolt 55 Nm
30. 30. Attach high pressure line, high pressure pump to pressure reservoir • Detach closure caps • Tighten 2x union nut – (M12) 25 Nm – (M14) 23 Nm

Note. Use new high pressure lines

31. 31. Connect wiring harness plug of high-pressure pump
32. 32. Attach fuel supply line high pressure pump • Fasten clamp
33. 33. Attach damping case, fuel return • Tighten 2x bolt • Attach fuel return line • Attach fuel hose – Fasten clamp • Connect oil leak line

Note. Must engage audibly

34. 34. Install air cleaner housing
35. 35. Install engine cover. • Clip in 4x
36. 36. Raise vehicle by its entire height
37. 37. Attach air drain hose for air cleaner housing
38. 38. Detach KM-6313-100 • Remove bolt • Detach support • Bolt 50 Nm – From compressor support
39. 39. Detach KM-6313
40. 40. Install lower right engine compartment cover and engine splash protector if necessary
41. 41. Lower vehicle by its entire height
42. 42. Connect battery. • Attach ground clamp to ground terminal – Tighten nuts
43. 43. Program volatile memories
44. 44. Close bonnet