Draining sediment, removing air from the filter (diesel models) (Opel Corsa C)

Note: Before performing any maintenance on the fuel filter, thoroughly wipe the area around the filter to prevent dirt from entering the fuel system. To collect any spilled fuel, place a rag under the filter or install a suitable drain container.

Caution: Do not allow diesel fuel to come into contact with the surfaces of the generator, starter, cooling system hoses, engine mounts and electrical wiring harnesses!

1. The fuel filter is installed on the rear bulkhead of the engine compartment.

Draining sludge/water

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. 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 (see accompanying illustrations). Try not to shake the filter so that the sediment does not mix with the top layer of fuel.

Note: If the housing fits very tightly and cannot be removed from the mounting clamp, remove the fuel filter together with the clamp (see Chapter 4).

4. Place a suitable container under the drain plug located at the bottom of the housing to collect the sediment/water. Loosen the drain plug by about 1 turn and allow the fuel to drain into the prepared container. Do not tighten the plug until clean fuel starts to flow out of the hose - usually about 100 ml is enough to drain.

Attention: The fuel should not be drained from the filter completely! After completing the operation, tighten the drain plug, fix the filter housing in its regular place and connect the plug connectors.

5. Remove the drain pan. Use a clean rag to wipe up any spilled fuel. Reconnect the battery. Finally, check the fuel lines and filter for leaks.

Note: After draining the sediment/water, it is not necessary to bleed the fuel system to remove air (see paragraph 17).

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 system plug connectors (if they were not disconnected when draining the fuel).

8. Disconnect all fuel hoses from the filter housing (see accompanying illustration), - try not to damage the special connectors, use a special tool from Opel for this (KM-796-A or Hazet 4501-1). To prevent fuel spillage and air from entering the fuel system after disconnecting, close the free ends of the hoses with plugs.



9. Remove the fuel filter housing from the mount by pushing it upwards.

10. To replace the filter element of engines with a working volume of 1.7 l, it is necessary to unscrew the tightening bolt (see accompanying illustration) and disassemble the filter. There is some fuel left in the replaceable element - after removing it, place it in a suitable container, and drain the remaining fuel from the filter housing there. Wipe the cover and filter housing with a clean rag.





11. Insert a new replacement filter element into the housing and fill the filter almost to the top edge of the housing with clean diesel fuel.

Caution: Even a small amount of sand and dirt on the inner surface of the replaceable element can cause the high-pressure fuel pump (HPFP) to fail. Replace the sealing gaskets, carefully assemble the filter and tighten the clamping bolt to 6 Nm.

Note: Do not apply too much force when tightening, otherwise the filter cover sealing gasket may be damaged.

12. The design of the filter for Z13DT engines is shown in the accompanying illustration 8. 12a. To replace the filter element, it is necessary to use a special device (Opel-EN-46784-020), clamp the filter housing in a vice, then, using the special key Opel-EN-46784-010 (see accompanying illustration 8.12b), release the filter cover clamping ring. If special devices are not available, secure the fuel filter housing in a vice using suitable pads or shaped jaws and release the clamping ring using a hammer and a wooden block - strike the block carefully, alternately adjusting it to the various projections of the ring.



(Material provided by this website: opelbook)

Attention: When disassembling the filter without using a special tool, be especially careful - you can damage the threads or edges of the pressure ring, which in turn will lead to a loss of seal tightness!

13. Remove the filter cover with the replaceable element, remove the sealing ring and, turning the replaceable element 50° counterclockwise, detach it from the cover. Wipe the cover and filter housing with a clean rag.



14. After replacing the replaceable element, assemble the filter in the reverse order - do not forget to replace the sealing gasket 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 into the mount, remove the plugs and connect the fuel hoses, then connect the electrical wiring to the filter and connect the battery.

16. After completing all operations with the fuel filter, start the engine and let it idle. Check the fuel system for leaks. If the engine does not start, remove air from the fuel supply system (see below).

Removal air from the fuel system

See also Chapter 4, Section 4.

17. Air will be removed from the system automatically when the ignition is turned on and the engine is started. 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 the ignition on and off three times, leaving it on for 15 seconds each time. When the ignition is turned on, the electric fuel pump is activated, with the help of which the fuel circulates throughout the entire fuel system circuit, air is removed and the fuel filter is filled. Repeat starting the engine - hold the ignition key until it starts, but not more than 30 seconds. If the engine does not start again, turn off the ignition and after a while repeat the air removal procedure.