Removal and installation of fuel injection pump (Opel Vectra C)

Caution: Do not allow dirt to enter the pump and fuel lines!

Z19DT(H) Engines

1. Disconnect the cable from the negative terminal of the battery.

2. Remove the timing belt.

3. Disconnect the supply lines from the fuel pressure pulsation damper (see accompanying illustration) unscrew 2 bolts and remove it.



4. Unscrew the bolt securing the fuel injection pump drive gear, holding the wheel from turning using special devices KM6347 and KM-956-1





5. Using a special device (see accompanying illustration) press the wheel off the injection pump shaft, using an assistant if necessary.

6. Disconnect the fuel pipes from the injection pump assembly, loosen the 3 fastening nuts and remove the injection pump housing.

7. Installation is carried out in reverse order.

Engines Y20DTH/Y22DTR

8. Operations for removing/installing the high-pressure fuel pump on these engines are performed only on a removed engine and therefore their description is not provided in this Manual.

Y30DT Engine

9. The high-pressure fuel pump is installed in the cylinder block collapse on the timing drive side.

To free access to it, it is necessary to dismantle all lines and units located above the collapse of the block. In the process of performing these operations (are not described here) you will have to remove quite a lot of small parts and lines - if necessary, it is recommended to contact an Opel service station.

10. Remove the lower cover and two timing gears (see Chapter 2, Section 8).

11. Install the special device (see accompanying illustration) screw the nut in until it stops, unscrew the locking bolt (M6), release the nut and remove the outer gear of the fuel injection pump. Remove the spring.





12. Reinstall the KM-6376 device (see illustration 18.11) screw 2 bolts (M6) into the holes of the internal gear, position the gear so that the bolt on the right (if you look at the gear) side is in the "2 o'clock" position, and the left bolt is in the "8 o'clock" position. Smoothly screw in the left and right bolts and press the internal gear of the fuel injection pump.

13. Disconnect the electrical wiring, unscrew the 4 mounting bolts (see accompanying illustration) and remove the fuel injection pump housing.



14. Installation is performed in the reverse order of removal. The same device is used to install the fuel injection pump gears. Secure the outer gear from turning with a screwdriver (see accompanying illustration), first tighten one bolt (M6) to hold the gear, press the device with a suitable tool (for example, with a second screwdriver) and screw in the second bolt, using the help of an assistant.

Text was copied from the portal [OpelBook]