High pressure fuel pump — removal and installation (Opel Vectra B)

1.7L engines

1. Remove the ground cable from the battery. Remove the intake manifold.

2. Remove the pulley from the fuel pump.

3. Remove the oil filter.

4. Remove the accelerator cable from the fuel pump.



5. Pinch the coolant supply hoses, loosen the clamps and remove both hoses from the fuel pump thermostat capsule (indicated by the arrow).

6. Disconnect the fuel hoses from the fuel pump and plug them.

7. Unscrew the couplings and remove the fuel lines connecting the fuel pump to the fuel injectors.

8. Disconnect the electrical connector from the engine stop solenoid valve control unit.

9. Using a marker or scriber, mark the protrusion of the front of the fuel pump relative to the bracket.



10. Remove the bolts (B) securing the rear part of the fuel pump to the cylinder block bracket. Remove the nuts (A) securing the front part of the fuel pump and remove the fuel pump.



11. Install the fuel pump onto the engine and loosely tighten the fuel pump mounting nuts and bolts.

12. Install the fuel pump on the bracket in accordance with the previously applied marks and pre-tighten the pump mounting nuts and bolts.

13. Install the fuel pump pulley and timing belt.

14. Adjust the fuel pump injection timing.

15. Install the fuel pipes connecting the fuel pump and fuel injectors.

16. Connect the electrical connector to the engine stop solenoid valve control unit.

[Material copied from this resource: www.opelbook.ru]

17. Connect the fuel supply and return hoses to the fuel pump.

18. Connect the coolant supply hoses to the fuel pump thermostat capsule.

19. Connect the accelerator cable to the fuel pump.

20. Install the intake manifold.

21. Install the oil filter and add engine oil to the engine.

22. Connect the battery, start the engine and check the fuel system for leaks.

23. Warm up the engine to operating temperature and adjust the idle speed if necessary.

2.0L engines

1. Remove the intake manifold.



2. Having unscrewed the mounting bolts (indicated by arrows), disconnect the fuel supply and return pipes from the high pressure fuel pump.



3. Remove the top chain and sprockets.



4. Through the hole in the lower sprocket, unscrew the mounting bolts (1) of the front part of the fuel pump.



5. Unscrew the bolts (indicated by arrows) and remove the mounting bracket from the rear of the fuel pump.



6. Remove the fuel pump together with the sealing ring (indicated by the arrow).



7. Before installation, check that the guard in the sprocket projection of the fuel pump is aligned with the hole in the pump body, and check that the camshaft and crankshaft are set to the position corresponding to the top dead center of the first cylinder in the compression stroke.

8. Install a new O-ring onto the fuel pump.

9. Install the fuel pump by aligning the lower chain sprocket with the pump boss and secure the pump with bolts. Install the rear fuel pump bracket and secure with bolts.

10. Install the top chain and sprockets.

11. Screw the fuel lines to the fuel pump.

12. Install the intake manifold.

13. Connect the battery, start the engine and check the fuel system for leaks.