High-Pressure Fuel Pump; Fuel Pressure Regulator; Fuel Pressure Sensor; Crankshaft Sensor - Opel Zafira B MPV 2006 Owners Workshop Manual

4A•12 Fuel and exhaust systems - petrol engines
14.45 Undo the two retaining bolts
(arrowed) and remove the fuel pressure
regulator from the fuel rail
22 Remove the old sealing ring and support
ring from the top of each injector and clean
the ring locations. Using the fitting sleeve of
tool KM-6364, fit a new support ring, then fit
a new sealing ring. Repeat this procedure for
the remaining injectors.
23 Using a circular movement, fit the four
injectors into the fuel rail and secure each one
with a new spring clip and plastic clip.
24 Refit the injector wiring harness and
reconnect the injectors, fuel pressure regulator
and fuel pressure sensor.
25 Clean the injector locations in the cylinder
head and remove the fitting tools from the
injectors. Refit the injector and fuel rail
assembly to the cylinder head.
26 Insert the four retaining bolts and tighten
them in a spiral sequence, in two stages to the
specified torque.
27
Refit the two stud bolts to the fuel rail and
tighten to the specified torque.
28 The remainder of refitting is a reversal of
removal, bearing in mind the following points:
a) Ensure that all wiring connectors are
securely reconnected, and that the
wiring is secured in the relevant clips and
brackets.
b) Tighten the high-pressure fuel pipe unions
to the specified torque.
c) On completion, reconnect the battery,
start
the engine and check for fuel
leaks. If
satisfactory, refit the engine cover.
High-pressure fuel pump
Removal
29 Disconnect the battery negative terminal
14.60 Disconnect the manifold pressure
sensor wiring connector (arrowed}
(refer to Disconnecting the battery in the
Reference Chapter).
30 Remove the plastic cover over the top of
the engine.
31 Depressurise the fuel system as described
in Section 5.
32 Disconnect the fuel return hose quick-
release connector at the high-pressure fuel
pump (see illustration 14.13b). Be prepared
for some loss of fuel. A Vauxhall/Opel special
tool is available to release the connector, but
provided care is taken, it can be released
using a pair of long-nosed pliers, or a similar
tool, to depress the retaining tangs. Suitably
cover or plug the open unions, to prevent dirt
ingress and further fuel spillage.
33 Thoroughly clean the fuel pipe unions
on the high-pressure fuel pump and fuel rail.
Using an open-ended spanner, unscrew the
union nuts securing the fuel pipe to the fuel
pump and fuel rail (see illustration 14.14). Be
prepared for some loss of fuel. Withdraw the
high-pressure fuel pipe and plug or cover the
open unions to prevent dirt entry.
34 Undo the three retaining bolts and remove
the high-pressure pump from the cylinder
head. Collect the gasket.
Refitting
35 Thoroughly clean the mating faces of the
cylinder head and fuel pump and locate a new
gasket on the pump.
36 Place the pump in position on the cylinder
head and refit the three retaining bolts. Tighten
the bolts to the specified torque.
37 Reconnect the fuel pipe to the pump
and fuel rail and tighten the union nuts to the
specified torque.
38 Reconnect the fuel return hose to the
pump.
39 Reconnect the battery, then start the
engine and check for fuel leaks.
40 Refit the engine cover on completion.
Fuel pressure regulator
Removal
41
Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
42 Remove the plastic cover over the top of
the engine.
43
Depressurise the fuel system as described
in Section 5.
44 Slacken the retaining clips securing the air
intake duct to the airflow meter and throttle
housing. Detach the intake duct from the
airflow meter and throttle housing, and remove
the duct from the engine.
45 Disconnect the wiring connector at the
fuel pressure regulator, then undo the two
retaining bolts and remove the regulator from
the fuel rail (see illustration). Be prepared for
some loss of fuel. Remove the two sealing
rings from the regulator.
Refitting
46
Fit two new sealing rings to the regulator,
then place the unit in position on the fuel rail.
Refit and tighten the retaining bolts to the
specified torque and reconnect the wiring
connector.
47 Refit the air intake duct and securely
tighten its retaining clips.
48 Refit the engine cover and reconnect the
battery.
Fuel pressure sensor
Removal
49 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
50 Remove the plastic cover over the top of
the engine.
51 Depressurise the fuel system as described
in Section 5.
52 Remove the cable tie, then disconnect the
wiring connector at the fuel pressure sensor
(see illustration 14.11a). Unscrew the sensor
and remove it from the fuel rail. Collect the
sealing ring.
Refitting
53 Refit the sensor to the fuel rail using a
new sealing ring, and tighten the sensor to the
specified torque.
54 Reconnect the wiring connector and
secure with a new cable tie.
55 Reconnect the battery, then start the
engine and check for fuel leaks.
56
Refit the engine cover on completion.
Coolant temperature sensor
57 Refer to Chapter 3 for removal and refitting
details.
Manifold pressure sensor
Removal
58 Remove the plastic cover over the top of
the engine.
59 Unclip the wiring harness connector
located above the manifold pressure sensor.
60
Disconnect the pressure sensor wiring
connector, undo the retaining bolt and remove
the sensor from the intake manifold (see
illustration).
Refitting
61
Refit the sensor to the manifold, refit the
retaining bolt and tighten to the specified
torque.
62 Reconnect the sensor wiring connector,
secure the wiring harness connector, and refit
the engine cover.
Crankshaft sensor
Removal
63 Remove the starter motor as described in
Chapter 5A.
64 Trace the wiring back from the sensor,
releasing it from all the relevant clips and ties
whilst noting its correct routing. Disconnect
the wiring connector from the sensor.
65 Unscrew the retaining bolt and remove
the sensor from the cylinder block (see illus-
tration).