Vauxhall Workshop Service and Repair Manuals

One Injector, Remove and Install

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

6.   Drain coolant •   Open drain bolt on radiator (1) •   Collect coolant •   Close drain bolt

9.   Remove engine cover (2) •   Detach oil filler port closure cap (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover •   Attach oil filler port closure cap

10.   Remove air cleaner housing (5) with air intake hose •   Detach wiring harness plug (2) from hot film mass air flow meter •   Detach air intake hose from air intake pipe – Release clamp (1) •   Detach air cleaner housing from wheel housing – Unscrew bolt (4) •   Detach water drain hose (3) from air cleaner housing – Release clamp

11.   Remove air intake manifold (1) •   Detach wiring harness – Release 3x clip •   Undo 2 clamps •   Unscrew 2x bolts

12.   Remove charge air pipe (1) •   Unscrew 6x bolts

13.   Detach wiring harness for injectors •   Disconnect 4x wiring harness plugs for injector (2) •   Unscrew 2x bolts (3) •   Disconnect 4x wiring harness plug for glow plug (1) with KM-717 •   Push wiring harness to one side

Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1) 15.   Remove high pressure lines (1), pressure chamber to injectors •   Unscrew 8x union nut with KM-812 or KM-6098 •   Take out pressure lines •   Seal 4x pressure chamber opening with protective cap •   Seal 4x injector opening with protective cap

16.   Detach fuel return line (1) •   Detach 4x fuel return line from injector – Press 4x retaining clamps in direction of arrow •   Detach fuel return line from pressure chamber •   Unscrew 2x bolts Note:   Note different bolt lengths •   Unscrew nut

17.   Remove rear right engine transport shackle (1) •   Unscrew 2x bolts

18.   Remove rear left engine transport shackle (1) •   Detach wiring harness – Unclip clip •   Unscrew bolt

19.   Remove bracket, oil dipstick guide tube (1) •   Unclip vacuum line – Unclip 2x clips •   Remove oil dipstick guide tube – Release clamp •   Detach bracket, oil dipstick guide tube, from camshaft housing – Unscrew 2x bolts

20.   Remove 4x seals, connection for injectors (1) •   Unscrew 8x bolts

21.   Remove 4x seal, injectors (1) •   Unscrew 8x bolts

22.   Remove camshaft housing cover (1) •   Unscrew 11x bolts Note:   Note different bolt lengths

23.   Remove injector (1) Note:   Mark injectors •   Remove injector bracket (2) – Unscrew bolt Note:   If a heat protection sleeve (5) also has to be removed when removing an injector, the gaskets (3) must be replaced and the heat protection sleeve must be hammered into the cylinder head with KM-6357 (4)

  Install

25.   Replace injector gaskets •   Rubber gasket (1) •   Copper gasket (2)

26.   Install 4x injector •   Install 4x brackets – Align injectors with EN-48560 (1)

28.   Fasten 4x injectors •   Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

32.   Apply sealing compound Important:   Oil return bore (2) may not be covered with adhesive sealing compound •   Apply adhesive sealing compound (white) to sealing surfaces (1) and (3)

33.   Install camshaft housing cover •   Replace gasket •   Tighten 9x bolt in the stated order (1...9) 9.8 Nm

34.   Install 4x new seal, injectors (2) •   Align seal for injectors Note:   Sealing lip of seal must be in full contact with the injector with no gaps (arrow) •   Coat 8x bolt head contact surface (1) with special grease (white) •   Tighten injector seal in 2 stages Note:   During the tightening process, press injector seal against the camshaft housing cover with your hand 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

35.   Install 4x new seal, connection for injectors Note:   Marking "UP" must point upwards •   Tighten 8x bolts