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Vauxhall Workshop Service and Repair Manuals

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Pulse Pick-Up > < Engine Z18XER, Simtec 75 (Rear electronic module)

Astra H

Injectors, Remove and Install

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Remove engine venting pipe (1)
•   Unclip wiring trough (2) from cylinder head cover
•   Disconnect 2x quick-release fitting
Object Number: 9007879 Size: DEFAULT


4.   Detach engine management wiring harness
•   Disconnect 9x wiring harness plugs
– Engine control unit
– Air mass flow meter
– Tank vent valve
– Throttle valve module
– Valve, intake camshaft adjustment
– 4x injector valve
•   Unclip 2x wiring harness bracket
•   Put wiring harness to side
5.   Place collecting basin underneath.
6.   Release fuel pressure via test connection (1) using KM-J-34730-91
•   Collect exiting fuel in a suitable container - observe safety regulations and national legislation
Object Number: 9007692 Size: DEFAULT


7.   Detach fuel return line (1)
•   Undo quick-release fitting with KM-796-A
•   Seal fuel line and fuel rail with KM-807
Object Number: 9007691 Size: DEFAULT


8.   Remove fuel rail (2)
•   Unscrew 2x bolts (1)
Object Number: 9007895 Size: DEFAULT


9.   Remove injectors
•   Detach 4x retaining clamps (1)
•   Pull out 4x injectors
Object Number: 2398387 Size: DEFAULT


  Install

10.   Attach 4x injector valve to fuel rail
•   Insert 4x new seal rings
– Coat seal ring with silicone grease
•   Insert 4x injection valves
•   Attach 4x retaining clamps
Note:   Check installation position and ensure correct fitting
11.   Install fuel rail
•   Tighten 2x bolt 8 Nm
12.   Attach fuel supply line to fuel rail
•   Remove 2x KM-807
•   Connect quick release fitting
•   Clip into bracket
13.   Attach engine management wiring harness
•   Connect 9x wiring harness plug
– Engine control unit
– Air mass flow meter
– Tank vent valve
– Throttle valve module
– Intake camshaft actuator
– 4x injector valve
•   Clip on 2x wiring harness bracket
14.   Install engine vent hose
•   Connect 2x quick-release fittings
•   Clip wiring harness to cylinder head
15.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
16.   Program volatile memories
17.   Close bonnet

Pulse Pick-Up > < Engine Z18XER, Simtec 75 (Rear electronic module)