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
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 resist. illustrations). Try not to shake the filter so that the sediment does not mix with the top layer of fuel.
Note: If the housing is very tight and cannot be removed from the mounting clamp, remove the fuel filter together with the clamp (see chapter 4).
8.3a. Fuel filter for Y17DT/Z17DTH engines: 1. Housing; 2. Plug connector for fuel heating system; 3. Drain plug; 4. Mounting clamp; 5. Guides; 6. Drain container
8.3b. Fuel filter engine Z13DT: 1. Plug connector for fuel heating system; 2. Plug connector for fuel temperature sensor (with appropriate equipment); 3. Tank for draining sludge; 4. Drain plug; 5. Filter housing
4. Place a suitable container under the drain plug at the bottom of the housing to drain the sludge/water. 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 - about 100 ml is usually sufficient.
Attention: The fuel must not drain completely from the filter! At the end of the operation, tighten the drain plug, fix the filter housing in its original place and dock the plug connectors.
5. Remove the waste container. Use a clean rag to pick up spilled fuel. Connect the battery. Finally, check the fuel lines and filter for leaks.
Note: It is not necessary to bleed the fuel system to remove air after draining the sediment/water (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 plug connections of the system (if they were not disconnected when draining the fuel).
8. Disconnect all fuel hoses from the filter housing (see resist. illustration), - try not to damage the special connectors, use a special tool from Opel 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.
8.8. Fuel filter (6) diesel engine (on the example of Z13DT) - the arrow indicates the plug connector of the fuel temperature sensor: 1. Plug connector for fuel heating system; 2. Electrical wiring connector for the engine management system; 3. Fuel supply hose; 4. Outlet fuel hose; 5. Return hose; 7. Mounting clamp
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.
8.10. Fuel filter design for Y17DT/Z17DTL engines (H): 1. Coupling bolt; 2. Sealing gasket; 3. Filter cover; 4. Cover gasket; 5. Replaceable filter element; 6. Filter housing
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.
Attention: Even a small amount of 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. The design of the filter for Z13DT engines is shown in Ref. illustrations 8. 12a. To replace the filter element, it is necessary using 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 special tools are not available, secure 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.
8.12a. Engine fuel filter design Z13DT: 1. Clamping ring; 2. Fuel filter cover; 3. Replaceable filter element; 4. Sealing gasket; 5. Filter housing; 6. Device for clamping the filter housing in a vise (Opel-EN-46784-020)
8.12b. Disassembly of the fuel filter for Z13DT engines: 1. Special key (Opel-EN-46784-010); 2. Clamping ring; 3. Device for clamping the filter housing in a vise (Opel-EN-46784-020)
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. If the engine does not start, bleed the air from the fuel supply system (see below).
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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