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Replace high pressure line (high pressure pump accumulator) (Z 17 DTH, with air conditioning, LHD) > < Pedal Sensor, Replace (Z 17 DTH, with AC, LHD)

Corsa C

High Pressure Pump, Replace (Z 17 DTH, With Air Conditioning, LHD)

  Remove

Important:   In vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting and must be recalibrated
1.   Open bonnet
2.   Disconnect battery
•   Detach ground cable
3.   Detach front right wheel
4.   Raise vehicle
5.   Remove right front wheel
•   Unscrew 5 bolts
6.   Raise vehicle
7.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600 Size: DEFAULT


8.   Attach KM-6394
•   Position KM-6394 (1) at the front on the front axle body
Note:   Both locating pins (arrows) must be seated in the holes in the front axle body
•   Push front bracket (2) in the direction of the arrow
•   Place rear bracket (4), right hand side, on front axle body
•   Attach rear bracket (3), left hand side
– Screw in 2x bolt
•   Tighten 6 bolts
Object Number: 2408346 Size: DEFAULT


Object Number: 2411021 Size: DEFAULT

9.   Install support
•   On KM-6394
– Adjust bracket (2) for support
•   Screw on nut (1)
10.   Adjust 3x support
•   Transmission side
Note:   Turn spindles until mounts (3) are positioned at guide journals free of play
•   Engine timing side
– Insert journal of the support in the bore of the cylinder block free of play (arrow)
– Tighten nuts (1)

11.   Loosen coolant pump ribbed V-belt pulley (1)
•   Undo 3 bolts
Object Number: 2406521 Size: DEFAULT


12.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
Note:   Mark running direction.
– Use KM-913-A
Object Number: 2411073 Size: DEFAULT


13.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3 bolts
14.   Lower vehicle
15.   Remove air cleaner housing
Object Number: 2408126 Size: DEFAULT

16.   Remove wiring trough
•   Unclip vacuum line (4)
•   Unclip wiring trough (5)
– 2 clips
•   Remove bolt (3)
•   Disconnect 2 wiring harness plugs
– Camshaft sensor (2)
– Charge pressure sensor (1)
•   Unclip wiring harness
17.   Remove camshaft sensor
•   Remove bolt (arrow)

18.   Remove right engine damping block (1)
•   Unscrew 4 bolts
Object Number: 2408139 Size: DEFAULT


19.   Detach right engine bracket (1)
•   Unscrew 3 bolts
Note:   Lower bolt cannot be removed
•   With right engine bracket adapter
Object Number: 2411072 Size: DEFAULT


20.   Remove upper toothed belt cover
Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover
•   Unscrew 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


21.   Raise vehicle
22.   Remove torsional vibration damper (1)
•   Unscrew 4 bolts
Object Number: 2411100 Size: DEFAULT


23.   Detach lower part of toothed belt cover
•   Unscrew 3 bolts
Object Number: 2411099 Size: DEFAULT


24.   Remove right engine bracket
25.   Set 1st cylinder to TDC
•   Turn crankshaft evenly until TDC fixing bolt (1) can be screwed in
Note:   Mark (3) on toothed belt drive gear must align with mark (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


26.   Loosen toothed belt tension roller (1)
•   Loosen bolt of toothed belt tension roller (2)
•   Rotate toothed belt tension roller anticlockwise approx. 90°
•   Tighten bolt of toothed belt tension roller
Object Number: 2406524 Size: DEFAULT


27.   Remove toothed belt
Note:   Mark running direction.
28.   Remove high pressure pump drive gear
•   Unscrew nut
– Counterhold with KM-6603 (1)
Note:   Allow KM-6603 to lie in position (2) against toothed belt drive gear
Important:   Note woodruff key
•   Disengage high pressure pump drive gear using KM-6602 (4)
– Counterhold with KM-6603
Note:   Allow KM-6603 to lie in position (3) against toothed belt drive gear
Object Number: 7360929 Size: DEFAULT


29.   Raise vehicle
30.   Remove 2 blank holders
•   Unscrew 2 nuts
•   Unscrew 4 bolts
•   Unscrew and remove 2 stud bolts
•   Detach ground cable
– Remove bolt
•   Disconnect 6 wiring harness plugs
•   Unclip vacuum line
•   Remove fuel line spacer
Important:   Be sure not to damage the high pressure line (2)
31.   Detach high pressure line (1) from high pressure pump at accumulator
•   Remove from bracket
– Remove bolt
•   Remove union nut from accumulator using KM-812 and from high pressure pump using KM-6098
– Unscrew 2 union nuts
•   Seal connection of high pressure pump
Object Number: 8132388 Size: DEFAULT


32.   Detach fuel supply line
•   Release clamp
33.   Detach fuel return line (1)
•   Unscrew banjo bolt
•   Unscrew nut
Object Number: 2408133 Size: DEFAULT


Important:   Be sure not to damage the high pressure line (2)
34.   Detach high pressure pump housing
•   Unscrew 2 nuts (1 and 3)
Object Number: 8132387 Size: DEFAULT


  Install

35.   Attach high pressure pump
•   Tighten 2 nuts 19.6 Nm
36.   Attach fuel return line
•   Replace 2x seal ring
•   Tighten banjo bolt 14.7 Nm
•   Tighten nuts
37.   Attach fuel supply line
38.   Install high pressure line
 

Diameter

Torque

Version 1

6.00 mm

30 Nm

Version 2

6.35 mm

25 Nm
Important:   Ensure that no dirt enters when inserting the line
•   Use KM-6098
– Tighten 2 nuts
•   Attach spacer
– Tighten bolt
39.   Fit 2 blank holders
•   Tighten 2 nuts
•   Tighten 4 bolts
•   Tighten 2 stud bolts
•   Connect ground cable.
– Remove bolt
•   Connect 6x wiring harness plugs
•   Unclip vacuum line
•   Fit fuel line spacer
40.   Lower vehicle
41.   Install high pressure pump drive gear
Note:   Note woodruff key
Note:   Counterhold with KM-6603
•   Tighten nut 68.6 Nm
42.   Install toothed belt
Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align.
•   Position toothed belt
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1)
– Note running direction
•   Loosen toothed belt tension roller (3)
•   Remove TDC locking bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten toothed belt tension roller 38Nm
Object Number: 2412651 Size: DEFAULT


43.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
•   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover
•   Screw in TDC fixing bolt (1)
Note:   If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC-fixing bolt
Object Number: 2412641 Size: DEFAULT


44.   Attach right engine bracket
•   Insert lower bolt
– Into right engine bracket and right engine bracket adapter
•   Fit right engine bracket with adapter
45.   Attach lower part of toothed belt cover
•   Tighten 3 bolts 9.8 Nm
46.   Lower vehicle
47.   Install upper toothed belt cover
•   Tighten 8 bolts 9.8 Nm
Note:   Note dissimilar bolt lengths
•   Clip in vacuum hose
48.   Fasten right engine bracket
•   Screw in 3 bolts
•   Tighten 2 upper bolts 40 Nm
49.   Install camshaft sensor
•   Replace seal ring
•   Tighten bolt 9.8 Nm
50.   Attach wiring trough
•   Route wiring harness
•   Clip-in wiring trough
•   Clip in vacuum hose
•   Tighten bolt 6 Nm
•   Connect 2 wiring harness plugs
51.   Install right engine damping block
•   To side member
– Tighten 2 bolts 40 Nm
•   On engine bracket
– Tighten 2 bolts 60 Nm+30°+15°
52.   Raise vehicle
53.   Fasten right engine bracket
•   Tighten lower bolt 40 Nm
54.   Attach coolant pump ribbed V-belt pulley
•   Screw in 3 bolts
55.   Install torsional vibration damper
•   Tighten 4 bolts 19.6 Nm
56.   Install ribbed V-belt
Note:   Observe running direction and installation position
•   Release tension from ribbed V-belt tensioner (1)
– I Ribbed V-belt without AC
– II Ribbed V-belt with AC
Object Number: 2415977 Size: DEFAULT


57.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 9.8 Nm
58.   Detach supports
59.   Detach KM-6394
60.   Attach ribbed V-belt cover
•   Tighten 3 bolts
•   Install clip
61.   Lower vehicle
62.   Attach front right wheel
•   Screw in 5 bolts
63.   Lower vehicle
64.   Fasten right front wheel
•   Tighten 5 bolts 110 Nm
65.   Install air cleaner housing
•   Fasten clamp 3.5 Nm
66.   Connect battery
Important:   Wear protective goggles
67.   Carry out leak test on high pressure system
Note:   Engine must be at operating temperature
•   Carry out actuator test (fuel leak)
•   Inspect high pressure system for fuel leak
68.   Close bonnet
69.   When replacing the high pressure pump:
•   Use TECH 2 to reset the learning values for the high pressure pump in the engine control unit
70.   Program volatile memory

Replace high pressure line (high pressure pump accumulator) (Z 17 DTH, with air conditioning, LHD) > < Pedal Sensor, Replace (Z 17 DTH, with AC, LHD)