Fule Rail; Counter-Hold Fuel Pipe Union On Pump With Second Spanner; Undo The Two Bolts At The Top; Move The Wiring Trough And Harness To One Side - Opel Zafira B MPV 2006 Owners Workshop Manual

48•8 Fuel and exhaust systems - diesel engines
12.25 Counter-hold the fuel pipe union
on the pump with a second spanner while
unscrewing the union nut
plug or cover the open unions to prevent dirt
entry.
22 Disconnect the injector leak-off pipe
and the fuel return quick-release fitting, then
undo the two bolts and remove the damping
chamber. Suitably plug or cover the open
unions to prevent dirt entry.
23 Disconnect the fuel return hose quick-
release fitting on the top of the high-pressure
fuel pump. Suitably plug or cover the open
unions to prevent dirt entry.
24 Disconnect the wiring connector from the
high-pressure fuel pump.
25 Thoroughly clean the fuel pipe unions
on the fuel pump and fuel rail. Using an
open-ended spanner, unscrew the union nuts
securing the high-pressure fuel pipe to the fuel
pump and fuel rail. Counter-hold the union
on the pump with a second spanner, while
unscrewing the union nut (see illustration).
Withdraw the high-pressure fuel pipe and plug
or cover the open unions to prevent dirt entry.
26 Unscrew the three retaining nuts and
remove the pump from the engine bracket
(see illustrations 12.Sa and 12.Sb).
Caution: The high-pressure fuel pump is
manufactured to extremely close tolerances
and must not be dismantled in any way. No
parts for the pump are available separately
and if the unit is in any way suspect, it must
be renewed.
Refitting
27 Refit the pump to the engine bracket and
tighten the retaining bolts to the specified
torque.
13.5a Undo the two bolts at the top
(arrowed) ...
28 Remove the blanking plugs from the fuel
pipe unions on the pump and fuel rail. Locate
a new high-pressure fuel pipe over the unions
and screw on the union nuts finger tight at this
stage.
29 Using a torque wrench and crow-foot
adapter, tighten the fuel pipe union nuts to the
specified torque. Counter-hold the union on
the pump with an open-ended spanner, while
tightening the union nut.
30 Reconnect the pump wiring connector
and the fuel return hose quick-release fitting.
31 Refit the damping chamber and tighten
the retaining bolts securely. Reconnect the
injector leak-off pipe, and the two remaining
fuel return hoses.
32 Refit the high-pressure fuel pump
sprocket and the timing belt as described in
Chapter 2D.
33 Reconnect the battery negative terminal.
34 Observing the precautions listed in
Section 2, prime the fuel system as described
in Section 5, then start the engine and allow it
to idle. Check for leaks at the high-pressure
fuel pipe unions with the engine idling. If
satisfactory, increase the engine speed to
4000 rpm and check again for leaks. If any
leaks are detected, obtain and fit a new
high-pressure fuel pipe(s).
35 Refit the windscreen cowl panel as
described in Chapter 11.
36 Refit the engine cover on completion.
A
Warning: Refer to the information
contained in Section 2 before
proceeding.
SOHC (Z19DT and DTL) engines
Note: A complete new set of high-pressure
fuel pipes will be required for refitting.
Removal
1
Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 Remove the windscreen cowl panel as
described in Chapter 11.
13.5b ... and the two bolts atthe front
(arrowed) and move the wiring trough and
harness to one side
3 Remove the plastic cover over the top of
the engine.
4 Release the locking catches securing the
wiring connectors to the four injectors, then
disconnect the injector wiring.
5 Undo the two bolts at the top and the
two bolts at the front, securing the plastic
wiring trough to the intake manifold (see
illustrations). Move the wiring trough and
injector wiring harness to one side.
6 Release the retaining clips and disconnect
the two fuel return hoses at the fuel return
damping chamber. Suitably plug or cover the
open unions to prevent dirt entry.
7
Disconnect the injector leak-off pipe and the
fuel return quick-release fitting, then undo the
two bolts and remove the damping chamber.
Suitably plug or cover the open unions to
prevent dirt entry.
8 Thoroughly clean the fuel pipe unions on the
fuel pump and fuel rail. Using an open-ended
spanner, unscrew the union nuts securing the
high-pressure fuel pipe to the fuel pump and
fuel rail. Counter-hold the unions on the pump
with a second spanner, while unscrewing the
union nuts. Withdraw the high-pressure fuel
pipe and plug or cover the open unions to
prevent dirt entry.
9 Using two spanners, hold the unions
and unscrew the union nuts securing
the high-pressure fuel pipes to the fuel
injectors. Unscrew the union nuts securing
the high-pressure fuel pipes to the fuel rail,
withdraw the pipes and plug or cover the open
unions to prevent dirt entry.
10 Disconnect the wiring connectors at
the fuel pressure regulator and fuel pressure
sensor, then undo the two nuts and remove
the fuel rail.
Refitting
11 Refit the fuel rail and tighten the retaining
nuts to the specified torque. Reconnect the
fuel pressure regulator and fuel pressure
sensor wiring connectors.
12
Working on one fuel injector at a time,
remove the blanking plugs from the fuel
pipe unions on the fuel rail and the relevant
injector. Locate the new high-pressure fuel
pipe over the unions and screw on the union
nuts finger-tight. Tighten the union nuts to the
specified torque using a torque wrench and
crow-foot adapter. Counter-hold the union
on the injector with an open-ended spanner,
while tightening the union nut. Repeat this
operation for the remaining three injectors.
13 Similarly, fit the new high-pressure fuel pipe
to the fuel pump and fuel rail, and tighten the
union nuts to the specified torque. Counter-hold
the union on the pump with an open-ended
spanner, while tightening the union nut.
14 Refit the damping chamber and tighten the
retaining bolts securely. Reconnect the injector
leak-off pipe, and the fuel return hoses.
15 Refit the wiring trough, and secure with
the four retaining bolts. Reconnect the wiring
connectors to the fuel injectors.
16 Reconnect the battery negative terminal.