Vauxhall Workshop Service and Repair Manuals

Change-Over Valve Housing, Remove and Install

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

Important:   After detaching the pressure line, seal off high pressure pump and pressure chamber openings with protective caps 1) 6.   Remove high pressure line (1) from high pressure pump to pressure chamber •   Unscrew 2x union nuts – From pressure chamber with KM-812 – From high pressure pump with KM-6098 •   Seal 2x opening with protective cap

7.   Detach wiring harness bracket (2) from pressure chamber •   Unscrew 2x nuts

9.   Remove engine cover (2) •   Detach oil filler port closure cap (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover •   Attach oil filler port closure cap

10.   Remove air cleaner housing (5) with air intake hose •   Detach wiring harness plug (2) from hot film mass air flow meter •   Detach air intake hose from air intake pipe – Release clamp (1) •   Detach air cleaner housing from wheel housing – Unscrew bolt (4) •   Detach water drain hose (3) from air cleaner housing – Release clamp

11.   Remove air intake manifold (1) •   Detach wiring harness – Release 3x clip •   Undo 2 clamps •   Unscrew 2x bolts

12.   Detach wiring harness for injectors •   Disconnect 4x wiring harness plugs for injector (2) •   Unscrew 2x bolts (3) •   Disconnect 4x wiring harness plug for glow plug (1) with KM-717 •   Push wiring harness to one side

13.   Remove charge air pipe (1) •   Unscrew 6x bolts

14.   Disconnect wiring harness plug (3) from pressure sensor 15.   Disconnect wiring harness plug (4) from vacuum unit change-over valves 16.   Detach vacuum line (1) from vacuum unit change-over valves 17.   Disconnect wiring harness plug (2) from charge pressure sensor

18.   Detach bracket, fuel damping unit (1) •   Unscrew 2x nuts (2) Note:   Tie bracket, fuel damping unit, with fuel line and damping unit, to bulkhead

Important:   After detaching the pressure lines, seal the apertures of the injectors and the pressure chamber with protective caps 1)   19.   Remove high pressure lines (1), pressure chamber to injectors •   Unscrew 8x union nut with KM-812 or KM-6098 •   Take out pressure lines •   Seal 4x pressure chamber opening with protective cap •   Seal 4x injector opening with protective cap

20.   Detach fuel return line (1) •   Detach 4x fuel return line from injector – Press 4x retaining clamps in direction of arrow •   Detach fuel return line from pressure chamber •   Unscrew 2x bolts Note:   Note different bolt lengths •   Unscrew nut

21.   Remove pressure chamber (4) •   Detach fuel return line from connection (2) •   Unscrew 2x bolts Note:   Note different lengths of the bolt (3) and spacer sleeves (1)

22.   Remove intake manifold •   Unscrew 8x bolts (1) •   Unscrew 2x nuts (2)

23.   Detach change-over valve housing from intake manifold •   Detach linkage (1) from change-over valve lever – Unclip retainer •   Unscrew 3x bolts (2)

  Install