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All High Pressure Lines, Replace (Injectors - Accumulator) > < Engine Management

Corsa C

Fuel Rail (Accumulator), Replace

Important:   Cleanliness is absolutely essential when working on the fuel system because even small dirt particles can lead to disruption to engine operation or the fuel system. Open fuel systems must be sealed with appropriate sealing plugs from the kit (45 06 154). Sealing plugs are only designed to be used once.

  Remove

1.   Open bonnet
Warning:   When working with the Common Rail Switch, wait one minute after switching off the engine. The system relieves the pressure itself.
2.   Waiting time for pressure relief
3.   Remove charge air pipe (1)
•   Release 2x clamp
•   Unscrew 2 bolts (arrows)
•   Unclip wiring harness
•   Detach hose
Object Number: 2406298 Size: DEFAULT


4.   Detach 4 high-pressure lines
•   Loosen 8 union nuts
5.   Detach high pressure line (2)
•   High-pressure line from high-pressure pump to fuel rail
•   Loosen 2 union nuts
6.   Detach fuel rail (1)
•   Disconnect 2 wiring harness plugs
– Pressure control valve, pressure sensor
•   Detach oil leak line
•   Detach 2 return lines
– Release clamp
•   Unscrew 2 bolts (arrows)
Object Number: 2406299 Size: DEFAULT


7.   Remove fuel rail attaching parts
•   Pressure sensor (2)
•   Pressure control valve (1)
•   Banjo bolt, oil leak line (3)
Object Number: 2406300 Size: DEFAULT


  Install

8.   Fit fuel rail attaching parts
•   Replace 2x seal ring
•   Tighten pressure sensor 70 Nm
•   Tighten pressure control valve 9 Nm
•   Tighten oil leak line banjo bolt
9.   Install fuel distributor pipe
•   Tighten 2 bolts
•   Attach 2 return lines
– Fasten clamp
•   Connect 2 wiring harness plugs
– Pressure control valve, pressure sensor
•   Connect oil leak line
10.   Attach high pressure line
•   Tighten 2 union nuts
– M14 28 Nm
– M12 24 Nm
11.   Attach 4 high-pressure lines
•   Tighten 8 union nuts
– M14 28 Nm
– M12 24 Nm
12.   Install charge air pipe
•   Screw in 2x bolt
•   Attach 2 clamps 3.5 Nm
•   Attach wiring harness
•   Attach hose
Important:   Wear protective glasses and gloves
13.   Check the fuel system for leaks
•   Start engine.
Note:   Check the fuel system for escaping fuel
14.   Close bonnet

All High Pressure Lines, Replace (Injectors - Accumulator) > < Engine Management