How to Replace (Replace Engine Control Unit) the Diesel Fuel Injection Pump Opel Vectra C

(Y 22 Dtr, with Air Conditioning, Rhd)

Important. Before removing the engine control unit with injection pump: perform reset with TECH2

1. 1. When replacing engine control unit with injection pump • Establish communication – Connect Tech 2

Note. Perform reset with TECH2 – see operation "Operations to be performed with TECH 2 when replacing control units" in group "N"

2. 2. Open bonnet
3. 3. Disconnect battery. • Detach ground cable

Important. Only open coolant compensation tank once engine has cooled down

4. 4. Unscrew coolant compensation tank closure cap
5. 5. Release right front wheel • Release 5x bolt
6. 6. Raise vehicle • Half height
7. 7. Disconnect right front wheel. • Unscrew 5x bolt
8. 8. Raise vehicle
9. 9. Remove lower engine cover (1) • Unscrew 10x bolt

10. 10. Drain coolant • Place collecting basin underneath. • Open drain bolt (arrow)

11. 11. Detach ribbed V-belt • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow) • Remove ribbed V-belt

Note. Mark direction of rotation

12. 12. Remove ribbed V-belt tensioner • Unscrew 2x bolt (1), (2)

Important. Damper (3) may only be stored in upright position. Incorrectly stored dampers may be bled by repeated compression in installation position.

13. 13. Close coolant drain bolt
14. 14. Detach coolant pipe (1) • Unscrew 2x bolt (arrows) • Detach heat exchanger coolant hose – Release clamp

15. 15. Lower vehicle
16. 16. Detach upper engine cover • Unscrew 3x bolt

Important. Carefully pull upwards

17. 17. Remove air intake hose (2) • Release 3x clamp
18. 18. Remove air cleaner housing (3) • Disconnect wiring harness plug for hot film mass air flow meter (1) • Pull bracket for solenoid valve and atmospheric pressure sensor upwards • Unclip wiring harness • Detach intake hose • Remove pollen filter housing (3)

19. 19. Detach upper charge air pipe (1) • Release 2x clamp • Unscrew 2x bolt (2)

20. 20. Remove connection hose from charge air pipe to intake pipe • Release 2x clamp
21. 21. Disconnect wiring harness plug for exhaust gas recirculation valve (1)

22. 22. Disconnect wiring harness plug for intake pipe pressure sensor (2)
23. 23. Detach intake pipe • Unscrew 4x bolt (1) • Remove bracket • Remove gasket.

Note. For engines with throttle valve vacuum unit (3): Detach vacuum hose

24. 24. Disconnect upper radiator hose • Release 2x clamp
25. 25. Remove preheater hose from thermostat housing to EGR valve • Release 2x clamp
26. 26. Remove preheater hose from EGR valve to heat exchanger • Release clamp • Set preheater hose to one side
27. 27. Detach 2x injection line spacer (arrows) • Unscrew 2x bolt

Note. Mark spacer position

28. 28. Remove 4x injection line (1) • Unscrew 8x union nut • Use KM-6098

Note. Note installation position.

29. 29. Detach upper part of intake manifold (2) • Unscrew 10x bolt

30. 30. Disconnect vacuum hose for switchover valve vacuum unit (1)
31. 31. Detach wiring harness plug bracket (2) • From crankshaft pulse pick-up • Remove bolt
32. 32. Detach lower part of intake manifold (3) • Unscrew 7x nut

33. 33. Detach coolant hose from thermostat housing to coolant pipe • Release clamp • Unclip wiring harness • Set coolant hose to one side

Important. Collect escaping fuel

34. 34. Detach 2x fuel line (1) • Disconnect leak oil hose (2) • Unscrew 2x banjo bolt (3) • Unclip 2x fuel line and lay aside

35. 35. Detach coolant line (2) • Unscrew 2x bolt • Release 2x clamp
36. 36. Remove brake servo vacuum line • Release and unclip brake servo vacuum line
37. 37. Detach wiring trough (1) • Unscrew 2x bolt • Unclip wiring harness • Lay wiring trough aside.

38. 38. Detach wiring harness bracket for engine management • Unscrew 2x bolt (arrows)

39. 39. Remove vacuum pump (2) • Detach vacuum hose • Unscrew 4x bolt (1) • Remove gasket (3)

40. 40. Detach vacuum line for turbocharger control vacuum reservoir solenoid valve • Unclip line and lay aside
41. 41. Disconnect cylinder head cover. • Unscrew 8x bolt • Remove gasket.
42. 42. Release timing case cover (1) • Unscrew 4x upper bolt
43. 43. Raise vehicle
44. 44. Remove timing case cover (1) • Unscrew 2x lower bolt

Important. Carefully separate timing case cover from timing case using wide spatula (2) Do not lever off timing case cover or use force to separate it from timing case, as permanent deformation results in leakage.

45. 45. Lower vehicle • Half height
46. 46. Preselect 1st cylinder TDC of combustion stroke

Note. Turn crankshaft uniformly in direction of engine rotation. Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

47. 47. Raise vehicle
48. 48. Remove crankshaft pulse pickup (1) • Unclip wiring harness • Remove bolt

49. 49. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

50. 50. Lower vehicle
51. 51. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

52. 52. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

53. 53. Remove Simplex chain tensioner (3) • Remove bolt (1), seal ring (2), chain tensioner (3)

Note. Note installation position.

54. 54. Remove guide rail for Simplex chain tensioner (1) • Remove 2x bolt (2) • Remove guide rail upwards

Important. Heat bolts intensively with hot air blower and unscrew. Use suitable heat shielding

Note. Note installation position.

55. 55. Remove KM-927 , KM-932
56. 56. Remove camshaft sprocket • Remove bolt

Note. Counterhold camshaft at hexagonal section. Attach Simplex timing chain at a suitable place.

57. 57. Remove Simplex injection pump gear • Unscrew 4x bolt (1) • Lower Simplex timing chain downwards • Remove Simplex injection pump gear at side • Remove Simplex timing chain upwards

58. 58. Raise vehicle
59. 59. Remove Duplex chain tensioner (3) • Remove bolt (1), seal ring (2), chain tensioner (3)

Note. Note installation position.

60. 60. Lower vehicle
61. 61. Detach wiring trough (1) • 3x clips • Lay wiring trough aside.

Important. Do not damage wiring trough (1)

62. 62. Release injection pump wiring harness • Lock 2x wiring harness plug for injection pump (1) in direction of arrow – Use KM-6154 (2) • Disconnect wiring harness plug for coolant temperature sensor • Unclip wiring harness

Important. Seal off 2x engine control unit connection

63. 63. Remove wiring trough bracket • Unscrew 2x bolt – From oil filter housing
64. 64. Release injection pump • Unscrew 4x bolt (1) • Use MKM-604-30
65. 65. Unscrew engine block coolant drain connection • Place collecting basin underneath.
66. 66. Remove injection pump • Unscrew cylinder block bolt – From bracket (2)

Important. A spacer washer (1) may be installed on the injection pump flange (2) to adjust the axial dimension. This spacer washer is allocated to the corresponding fuel injection pump and must always be left on the fuel injection pump flange. When installing a new fuel injection pump, this is supplied with the axial dimension adjusted, i.e. with or without spacer washer (1)

67. 67. Insert injection pump. • Replace seal ring • Screw in 4x bolt (3)

Note. Coat with silicon grease (white)

Important. When replacing the injection pump, the protective caps that are located on the plug connections for pump and engine control unit on delivery may only be removed immediately before connecting the plugs. Only in this way can it be ensured that no contact is bent or broken off, which could lead to malfunction of the pump and control unit assembly.

68. 68. Secure injection pump • Tighten 4x bolt (3) – Use MKM-604-30 – Tightening torque 25 Nm • Attach injection pump bracket – Tightening torque 20 Nm

69. 69. Screw in engine block coolant drain connection • Replace seal ring
70. 70. Attach wiring trough bracket • Tighten 2x bolt – Tightening torque 20 Nm
71. 71. Attach wiring trough • 3x clips
72. 72. Attach injection pump wiring harness • Remove 2x protective cap • Connect 2x wiring harness plug for injection pump and lock • Connect wiring harness plug for coolant temperature sensor • Attach wiring harness

Important. Arrow (2) on Simplex fuel injection pump gear must align with recess in fuel injection pump flange and retaining bore (3) in fuel injection pump.

73. 73. Install Simplex injection pump gear • Use KM-927 (4)

Note. Insert Simplex timing chain with Simplex fuel injection pump gear and hand-tighten Simplex fuel injection pump gear with fastening bolts (1). Ensure bolt strength 10.9 of the fastening bolts

74. 74. Raise vehicle
75. 75. Install Duplex chain tensioner (3) • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position. Close side of chain tensioner (3) must point to tension rail

76. 76. Lower vehicle
77. 77. Tighten Simplex injection pump gear • Remove KM-927 • Tighten 4x bolt – Tightening torque 28 Nm
78. 78. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

79. 79. Insert camshaft sprocket • Replace bolt • Position Simplex timing chain • Screw in bolt

Important. Ensure that camshaft sprocket is seated squarely on camshaft – camshaft sprocket must sit flat against camshaft.

80. 80. Install guide rail for Simplex timing chain (1) • Replace 2x bolt (2) • Tighten 2x bolt – Tightening torque 8 Nm

Important. Note installation position of guide rail

81. 81. Attach KM-933 (4) • Insert carrier (1) • Screw in 2x bolt

Note. Position upright in camshaft pulley

Important. It must be possible to remove and install KM-927 under suction. If this is not possible, the pressure on the adapter plate must be slightly reduced using the adjustment screw (3).

82. 82. Adjust KM-933 (4)

Note. Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

83. 83. Secure camshaft sprocket • Tighten bolt – Tightening torque 90 Nm + 60° + 30°
84. 84. Install Simplex chain tensioner (3) • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position.

85. 85. Remove KM-927 , KM-932 , KM-933 • Remove KM-933 – Unscrew 2x bolt – Remove carrier
86. 86. Raise vehicle • Half height
87. 87. Remove KM-929
88. 88. Turn crankshaft

Note. Turn crankshaft slowly and uniformly two rotations (720°) in direction of engine rotation until just before 1st cylinder TDC of combustion stroke Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

89. 89. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

90. 90. Lower vehicle • Half height
91. 91. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

92. 92. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

93. 93. Remove KM-932 , KM-927
94. 94. Raise vehicle
95. 95. Remove KM-929
96. 96. Install crankshaft pulse pick-up • Replace seal ring • Tighten bolt – Tightening torque 8 Nm • Route cable

Important. The application of silicone sealing compound (grey), installation of timing case cover and tightening to torque must be performed within 10 minutes.

97. 97. Install timing case cover • Screw in 3x bolt at bottom

Note. Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound (grey) to timing case cover.

98. 98. Lower vehicle
99. 99. Secure timing case cover • Tighten 6x bolt – Tightening torque 6 Nm
100. 100. Attach cylinder head cover • Replace gasket • Tighten 8x bolt – Tightening torque 8 Nm

Note. Gasket (2) must be inserted in gap (1) between cylinder head cover and sleeve. Apply wetting agent (colourless) to sealing surfaces (arrows).

101. 101. Attach vacuum line for turbocharger control vacuum reservoir solenoid valve • Clip in line

Note. The vacuum connections for the vacuum pump on the solenoid valves are marked with a "YELLOW" ring or with the designation "VAC" on the solenoid valves.

102. 102. Install vacuum pump • Replace gasket • Connect vacuum hose. • Tighten 4x bolt – Tightening torque 8 Nm
103. 103. Attach wiring harness bracket for engine management • Tighten 2x bolt
104. 104. Attach wiring trough • Attach wiring harness • Tighten 2x bolt
105. 105. Attach brake servo vacuum line • Clip in and lock brake servo vacuum line
106. 106. Attach coolant line • Tighten 2x bolt • Secure 2x clamp
107. 107. Attach 2x fuel line • Replace 4x seal ring • Tighten 2x banjo bolt – Tightening torque 15 Nm • Connect leak oil hose • Clip in 2x line
108. 108. Attach coolant hose from thermostat housing to coolant pipe • Fasten clamp • Attach wiring harness
109. 109. Attach lower part of intake manifold • Replace gasket • Replace 7x nut • Tighten 7x nut – Tightening torque 22 Nm
110. 110. Install wiring harness plug bracket • From crankshaft pulse pick-up • Tighten bolt
111. 111. Connect vacuum hose to switchover valve vacuum unit
112. 112. Attach upper part of intake manifold • Replace gasket • Tighten 10x bolt – Tightening torque 8 Nm
113. 113. Install 4x injection line • Hand-tighten 8x union nut • Tighten 8x union nut – Use KM-6098 – Tightening torque 30 Nm

Note. Check cones on fuel injection lines and replace if necessary. Note installation position

Important. Attach injection lines free of tension to injection pump and injection nozzle traverse

114. 114. Attach 2x injection line spacer • Tighten 2x bolt

Note. Note installation position.

115. 115. Install preheater hose from EGR valve to heat exchanger • Fasten clamp
116. 116. Install preheater hose from thermostat housing to EGR valve • Secure 2x clamp
117. 117. Connect upper radiator hose • Secure 2x clamp
118. 118. Attach intake pipe • Replace gasket • Position upper engine cover bracket • Tighten 4x bolt – Tightening torque 8 Nm

Note. For engines with throttle valve vacuum unit: Connect vacuum hose

119. 119. Connect wiring harness plug for intake pipe pressure sensor
120. 120. Connect wiring harness plug for exhaust gas recirculation valve
121. 121. Install connection hose from charge air pipe to intake pipe • Tighten 2x clamp – Tightening torque 3,5 Nm
122. 122. Attach upper charge air pipe • Secure 2x clamp – Tightening torque 3,5 Nm • Tighten 2x bolt – Tightening torque 3 Nm
123. 123. Install air cleaner housing • Clip in bracket for solenoid valve and atmospheric pressure sensor • Attach wiring harness • Install suction hose • Connect wiring harness plug to hot film mass air flow meter
124. 124. Install air intake hose. • Secure 3x clamp – Tightening torque 3,5 Nm
125. 125. Install upper engine cover • Clip in upper engine cover • Tighten 3x bolt
126. 126. Raise vehicle
127. 127. Fasten coolant pipe • Tighten 2x bolt • At cylinder block – Tightening torque 35 Nm • Attach heat exchanger coolant hose – Fasten clamp
128. 128. Install ribbed V-belt tensioner • Tighten 2x bolt – Tightening torque (M8) 20 Nm – Tightening torque (M10) 42 Nm
129. 129. Attach ribbed V-belt • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)

Note. Note running direction

130. 130. Install lower engine cover • Tighten 10x bolt
131. 131. Lower vehicle • Half height
132. 132. Attach right front wheel • Screw in 5x bolt
133. 133. Lower vehicle
134. 134. Secure right front wheel • Tighten 5x bolt – Tightening torque 110 Nm
135. 135. Top up coolant • Observe specified coolant quantity

Note. Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed"

136. 136. Check engine oil level, if necessary correct. • Observe specified engine oil quantity
137. 137. Connect battery. • Connect ground cable.
138. 138. When replacing engine control unit with injection pump • Reprogram engine control unit The engine control units supplied by Aftersales are programmed for ECOService Flex. ECOService Flex: up to 2 years/30.000 km petrol engine (up to max. 34.000 km possible) up to 2 years/50.000 km diesel Exception: ECOService: 1 year/30,000 km 1 Engine control unit (ECM) must be replaced. 2 Is the necessary documentation available? – Service Booklet – ECM/instrument assembly can still be read out – Customer records, invoices available 3 Time or distance exceeded, for ECOService 30000 km/2 years Fixed interval for petrol and diesel engine or ECOService, 30000 km/1 year Fixed interval for petrol and diesel engine 4 Determine whether ECOService or ECOService Flex 5 Complete sticker and affix (1 year/30000 km) 6 Instrument assembly programmed to ECOService 7 Selection, petrol engine or diesel engine 8 Complete sticker and affix (2 years/30,000 km, petrol engine) 9 Complete sticker and affix (2 years/30000 km, diesel engine) 10 Oil change necessary 11 Dealer agreement with customer 12 Decision (customer request) ECOService or ECOService Flex 13 ECOService (Program instrument assembly) 14 ECOService Flex Reset the remaining time with TECH 2 - ECOService Flex = ECOService Y Yes No No – see operation "Operations to be performed with TECH2 when replacing control units" in group "N" – CAN configuration list, version coding, tyre size • End communication – Disconnect Tech 2

Note. After installing the engine control unit with injection pump: Reprogram engine control unit

Note. For additional information see operation "Flexible Maintenance Intervals"

139. 139. Fill in service sticker

Note. Fill in service sticker – see operation "Flexible Maintenance Intervals"

140. 140. Fuel system, bleed

Note. See operation "Fuel System, Bleed (Diesel Engines)" in group "L"

141. 141. Close bonnet
142. 142. Program volatile memories