Note: Before beginning any fuel filter maintenance procedures, thoroughly wipe the area around the fuel filter seat to prevent the risk of dirt entering the fuel system path. To collect spilled fuel, place a rag under the filter, or install a suitable drain container.
Attention: Do not allow diesel fuel to get on the surfaces of the generator, starter, cooling system hoses, engine mounts and wiring harnesses!
1. The fuel filter is installed on the rear bulkhead of the engine compartment.
Sludge/Water Drain
Attention: If the corresponding warning lamp is activated (see chapter «Controls and methods of operation «, Section 16) perform the procedure for draining water from the fuel filter as soon as possible! Observe the regulations for the disposal of drained diesel fuel!
2. Before draining the sediment from the fuel filter, it is necessary to disconnect the terminal clamps from the battery, observing the requirements given in Chapter 5.
3. On engines with a displacement of 1.3 and 1.9 liters (see resist. illustration) disconnect the plug connectors of the fuel heating system and the fuel temperature sensor (with appropriate equipment). Then, without disconnecting the fuel hoses, remove the filter housing from the mounting clamp. Place a suitable container underneath to drain the sludge/water.
Note: Try not to shake the filter so that the sediment does not mix with the top layer of fuel.
Loosen the drain plug about 1 turn and allow the fuel to drain into the prepared container. Do not tighten the plug until clean fuel comes out of the hose - usually draining about 100 ml is enough.
Attention: The fuel must not drain completely from the filter.
At the end of the operation, fix the filter housing in its original place and dock the plug connectors.
4. On Z17DT engines (L/H) to drain sediment / water from the fuel filter, it must be put on the drain valve (see resist. illustration) in the lower part of the filter housing, a piece of hose of a suitable size - lower the other end of the hose into a clean container with transparent walls. Slightly loosen the pinch bolt on the filter cover and then the valve. Draining of sludge/water is done as described above. At the end of the operation, close the valve and tighten the pinch bolt on the filter cover (6 Nm).
Note: Do not overtighten, otherwise sealing gasket may be damaged and leakage will occur.
It is not necessary to bleed the fuel system to remove air after draining the sediment/water (see paragraph 17).
5. Remove the waste container. Use a clean rag to pick up spilled fuel. Connect the battery. Finally, check all weakened components for signs of leak development.
Replacing the working element of the fuel filter
6. Disconnect the battery and completely drain the fuel from the filter (see above).
7. Disconnect all plug connections of the system (if they were not disconnected when draining the fuel).
8. Disconnect the fuel hoses from the filter housing (see resist. illustration) - try not to damage the special connectors, use a special tool for this (KM-796-A or HAZET 4501-1). After disconnection, close the free ends of the hoses with plugs to avoid fuel spillage and air ingress into the fuel system.
9. Slide upwards and remove the fuel filter housing from the mount.
10. To replace the filter element of engines with a working volume of 1.7 l, it is necessary to unscrew the coupling bolt (see resist. illustration) and disassemble the filter. A certain amount of fuel remains in the replaceable element - after removing it, put it in a suitable container, drain the remaining fuel from the filter housing there. Wipe the cover and filter housing with a clean cloth.
11. Insert a new replacement filter element into the housing and fill the filter almost to the upper edge of the housing with clean diesel fuel (approx. 200 ml).
Attention: Sand and dirt on the inner surface of the replacement element can lead to failure of the high pressure fuel pump (injection pump).
Replace the gaskets, assemble the filter carefully and tighten the pinch bolt to 6 Nm.
Note: Do not overtighten, otherwise the sealing gasket of the filter cover may be damaged.
12. Filter design for Z 13 DTH/Z 19 DT engines (J/H) presented on ref. illustrations 8.12a. To replace the filter element, it is necessary to use a special tool (Opel-EN-46784-020) clamp the filter housing in a vise, then using a special key (Opel-EN-46784-010) (see resist. illustration 8.12b) Release the pressure ring on the filter cover. If there are no special tools, fix the fuel filter housing in a vise using suitable gaskets or curly jaws and release the clamping ring with a hammer and a wooden block - strikes on the block should be applied carefully, alternately fitting it to the various protrusions of the ring.
Attention: When disassembling the filter without using a special tool, be especially careful - you can damage the thread or the edges of the clamping ring, which in turn will lead to a violation of the tightness of the seal!
13. Remove the filter cover with replaceable element, remove the O-ring, and by turning the replaceable element 50°counterclockwise, disconnect it from the cover. Wipe the cover and filter housing with a clean cloth.
14. After replacing the replaceable element, the filter is assembled in the reverse order - do not forget to replace the seal and fill the filter with fuel.
Note: The filter cover can only be installed in the housing in one position to avoid incorrect assembly.
The clamping ring is tightened with a force of 30 Nm.
15. After assembling the filter, carefully install it in the mount, remove the plugs and connect the fuel hoses, then connect the electrical wiring to the filter and connect the battery.
16. Upon completion of all operations with the fuel filter, it is necessary to start the engine and let it idle. Check the fuel system for leaks.
Bleeding air from the fuel system
See also Chapter 4, Section 4.
17. Air will be removed from the system automatically when turned on «ignition» and starting the engine. If there is too little fuel in the filter, the engine may not start or the engine may stop shortly after starting. In this case, turn it on and off three times «ignition» each time leaving it on for 15 seconds. When turned on «ignition» the electric fuel pump is activated, with the help of which fuel circulates throughout the fuel circuit, air is removed and the fuel filter is filled. Restart the engine - hold the ignition key until the start occurs, but no more than 30 seconds. If the engine does not start again, turn off «ignition» and after a while repeat the bleed procedure.
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