Vauxhall Workshop Service and Repair Manuals

High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace

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

3.   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

4.   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

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

6.   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

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

Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1) 8.   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

  Install