Vauxhall Workshop Service and Repair Manuals

Replacing accumulator

Important:   Cleanliness is of the utmost importance when working with the fuel system. The smallest particle of dirt could cause engine malfunction or contaminate the fuel system. Open fuel systems must be sealed with a suitable plug from the Opel Parts catalogue (Cat. no. 45 06 154 / Part no. 9201697). Plugs are intended for one-time use only

  Remove

3.   Remove air cleaner housing (1) •   Disconnect wiring harness plug of hot film mass air flow meter (3) – Release in direction of arrow •   Remove air intake hose (4) – Loosen clamp (5) •   Remove bolt (2) •   Disconnect wiring harness

4.   Remove engine cover (2) •   Unscrew 2 bolts (1) •   Detach oil filler port cover (3) •   Unclip engine cover from bracket •   Attach oil filler port cover

8.   Unscrew oil filter housing cover (1) with oil filter

9.   Detach fuse holder (1) from bracket 10.   Remove coolant compensation tank (2) •   Detach 3 coolant hoses – Release 3x clamp •   Remove bolt •   Remove body-bound rivet •   Unclip from upper front

11.   Remove engine management wiring harness •   Disconnect 3 wiring harness plugs (arrows) – Engine control unit – 2 combination plugs •   Detach ground cable from engine control unit – Unscrew nut •   Expose wiring harness

12.   Remove air intake pipe •   Detach from turbocharger – Release clamp •   Unscrew 2 bolts •   Detach engine vent hose from camshaft housing – Release clamp •   Unclip wiring harness

13.   Remove engine control unit (1) •   Disconnect wiring harness plug •   Unscrew 2 bolts •   Unscrew 2 nuts

14.   Remove engine control unit bracket (1) •   Cut 3 cable ties •   Unscrew 4 bolts

15.   Remove engine control unit bracket support (1) •   Unscrew 2 bolts

16.   Disconnect engine wiring harness •   Disconnect 4 wiring harness plugs for injectors (4) •   Disconnect wiring harness plug of vacuum unit switchover valve (1) •   Disconnect wiring harness plug of charge pressure sensor (2) •   2x unclip bracket •   Separate cable tie •   Disconnect 4 wiring harness plugs for glow plugs (3)

17.   Remove charge air pipe (1) •   Unscrew and remove 3 stud bolts •   Unscrew 3 bolts •   Unscrew nut •   Remove 2 gaskets

19.   Detach fuel return line (1) •   Unscrew banjo bolt and nut (2) •   Release clamp

21.   Detach oil return hose (1) •   Release 2x clamp

22.   Remove 2 blank holders •   Unscrew 2 nuts (1) •   Unscrew 4 bolts (2) •   Unscrew 2 stud bolts (arrows) •   Detach ground cable – Remove bolt •   Disconnect 6 wiring harness plugs •   Unclip vacuum line •   Remove fuel line spacer (3)

Important:   Be sure not to damage the high pressure line (2) 23.   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

24.   Detach 4 high pressure lines (1) from accumulator to injectors •   Unscrew 8 union nuts (3) Note:   Seal off the high pressure lines and injectors •   Remove 2 high pressure line spacers (2) 25.   Remove accumulator Note:   Note differing bolts •   Unscrew 2 bolts (arrows)

  Install