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High Pressure Pump, Remove and Install
Warning: When
working on the Common Rail system, wait for one minute after
switching off the engine. The system reduces the pressure
automatically.
Important: When
working on the fuel system, cleanliness is vital as even very small
particles of dirt can lead to faults in engine operation or in the
fuel system. Seal open fuel connections with suitable sealing plugs
1) . Sealing plugs must only be used once.
 Remove
| 2. |
Disconnect battery
| • |
Detach ground connection from ground terminal
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| 4. |
Remove charge air hose from intercooler to charge air pipe
(1)
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| 5. |
Remove air intake pipe (2)
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Unclip 3x wiring harnesses
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| • |
Detach engine vent hose (1)
| – |
Disconnect quick-release fitting
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| • |
Detach from turbocharger air intake hose
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| • |
Detach from air intake hose, air mass flow meter
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| 6. |
Place collecting basin underneath.
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| 7. |
Remove fuel supply line (2)
| • |
Undo quick-release fitting with KM-796-A
| – |
Seal fuel line with KM-807
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| – |
Seal high pressure pump
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| 8. |
Detach fuel return line (1) from high pressure pump
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| 9. |
Remove high pressure line (1)
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| 10. |
Remove high pressure pump (1)
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Disconnect wiring harness connector (3)
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| • |
Unscrew 3x bolts (2)
Note: Note carrier
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Install
Important: Charge air hoses and
connection ports must be free from oil and grease.
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| 11. |
Install high pressure pump
| • |
Tighten 3x bolt 15 Nm
Note: Note carrier,
bevelled side points towards camshaft
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| • |
Connect wiring harness plug
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| 12. |
Install high pressure line
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Use new high pressure line
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| • |
Tighten union nut M14 on accumulator 28
Nm
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| • |
Tighten union nut M12 on high pressure pump 24 Nm
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| 13. |
Attach fuel return line to high-pressure pump
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| 14. |
Attach fuel supply line
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Connect quick release fitting
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| 15. |
Install air intake pipe.
| • |
Attach to turbocharger air intake hose
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| • |
Attach air mass flow meter to air intake hose
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| • |
Attach engine venting hose
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| • |
Clip in 3x wiring harnesses
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| 16. |
Install charge air hose, intercooler to charge air pipe
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Tighten 2x clamp 3.5 Nm
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| 18. |
Connect battery
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Attach ground connection to ground terminal
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| 19. |
Program volatile memories
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1 ) Protective caps are available in the Opel parts
catalogue under catalogue number: 45 06 154 / part number: 9201697
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