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Vauxhall Workshop Service and Repair Manuals

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Metering Unit, Replace > < High-Pressure Pump, Remove and Install

Corsa D

Replace fuel return line

Important:   When working on the fuel system maintaining cleanliness is essential, otherwise the smallest particles of dirt may result in engine operating faults or faults in the fuel system. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach negative clamp from earth terminal
– Undo nut
3.   Remove engine cover
4.   Place collecting basin underneath.
5.   Detach fuel return line (1) from injector
•   Release 4x retaining clamps (2)
•   Seal off line and connections with sealing caps
Object Number: 10679191 Size: DEFAULT


6.   Detach fuel return line (2) from accumulator
•   Detach from pressure chamber (3)
– Release clamp
•   Detach fuel return line bracket (1)
– Unscrew bolt
•   Seal off line and connections with sealing caps
•   Unclip 4x from toothed belt cover
Object Number: 10678267 Size: DEFAULT


7.   Raise vehicle by its full height
Object Number: 25571551 Size: DEFAULT

8.   Detach fuel return line (3)
•   Release clamp (1)
•   Unclip bracket (2)

  Install

9.   Install fuel return line
•   Fasten new clamp
•   Place fuel return line on top
•   Clip into bracket
10.   Lower vehicle by its full height
11.   Attach fuel return line to accumulator
•   Detach closure caps
•   Attach to pressure chamber
– Fasten new clamp
•   Attach fuel return line bracket
– Tighten bolt 7 Nm
•   Clip 4x in toothed belt cover
12.   Attach fuel return line to injector
•   Detach closure caps
•   Replace 4x seal rings
•   Fasten 4x retaining clamps
13.   Install engine cover
14.   Connect battery
•   Attach earth clamp to earth terminal
– Tighten nut
15.   Program volatile memories
16.   Close bonnet

Metering Unit, Replace > < High-Pressure Pump, Remove and Install