Vauxhall Workshop Service and Repair Manuals

J496000 Injector Nozzles, Remove and Install (Y 17 DTL, without AC, LHD)

1. Open bonnet

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. Disconnect battery

• Detach ground cable

3. Remove air cleaner housing (1) Remove wiring harness plug for hot film mass air flow meter (3) Release in direction of arrow Remove air intake hose (4) Loosen clamp (5) Remove bolt (2)

4. Remove wiring harness plug for engine control unit

• 3 off
• Release 2 wiring harness plugs in direction of arrow

5. Remove air intake pipe Remove 3 bolts Remove vent hose (1) From cylinder head cover Release clamp Unclip wiring harness

6. Remove engine control unit Remove wiring harness plug bracket (1) Remove 2 bolts Unscrew 2 bolts (2), 2 nuts (3)

7. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness

8. Remove right rear engine transport shackle

• Remove bolt

9. Loosen left rear engine transport shackle

10. Remove injection lines

• From injector nozzles

11. Remove outer injector nozzle seals Remove 8 bolts

12. Remove oil dipstick guide tube bracket

• Unscrew 2 nuts, bolt

13. Remove camshaft housing cover Unscrew 9 bolts (1), 3 studs (2)

14. Remove camshaft housing cover

• Note! 2. mechanic
• Carefully push injection line to rear

15. Detach inner oil leak line Unscrew 5 banjo bolts (1) Note! Note sealing rings

16. Remove injector nozzles Caution! Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head. Otherwise, heat protection sleeves must be removed completely and installed again using new seal rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head". Remove injection nozzle bracket (1) Remove 2 nuts Remove injector nozzles

17. Install injector nozzles Replace seal rings (1) Replace copper seal rings (2) Insert injection nozzles in cylinder head. Install injector nozzle bracket (22.1 Nm/16.3 lbf. ft.)

18. Attach inner oil leak line

• Renew seal rings
• Tighten banjo bolt (14.7 Nm/10.8 lbf. ft.)

19. Install camshaft housing cover. Replace gasket Apply adhesive sealant compound (white) Areas (1, 3) Caution! Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket

20. Install camshaft housing cover

• Note! 2. mechanic
• Carefully push injection line to rear

21. Tighten camshaft housing cover

• Tighten bolts, studs (9.8 Nm/7.2 lbf. ft.)

22. Install oil dipstick guide tube bracket

• Tighten nuts, bolt

23. Install outer injector nozzle seals

• Replace seals
• Tighten bolts

24. Install injection lines

• Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

25. Fasten left rear engine transport shackle

• Tighten bolts (20 Nm / 15 lbf. ft.)

26. Install right rear engine transport shackle

• Tighten bolt (20 Nm / 15 lbf. ft.)

27. Install engine control unit bracket

• Tighten bolts
• Attach wiring harness

28. Install engine control unit

• Tighten bolts, nuts (5.9 Nm/4.4 lbf. ft.)
• Install wiring harness plug bracket
• Tighten bolts

29. Install air intake pipe

• Tighten bolts
• Fasten clamp
• Attach engine vent hose
• Fasten clamp
• Attach wiring harness

30. Attach engine control unit wiring harness plug

• 3 off

31. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
• Connect wiring harness plug to hot film mass air flow meter

32. Connect battery

33. Calibrate steering angle sensor

• Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

34. Program volatile memories

35. Close bonnet