Vauxhall Workshop Service and Repair Manuals

Replace injectors

Warning:   When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important:   When working on the fuel system, cleanliness is vital as even very small particles of dirt can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs must only be used once.

Note:   Injectors can also be replaced individually. When replacing one or all the injectors, the IMA code of the injectors must be programmed in using TECH 2 in the engine control unit

  Remove

1.	Remove fuel high pressure lines, accumulator - injector

2.   Disconnect 4x wiring harness plugs for injector (1)

3.   Detach leak oil line (1) •   Unlock 4x retaining clamps (2) in direction of arrow

4.   Remove 4x injector (3) •   Detach 2x bracket (2) – Unscrew 2x nuts (1) Note:   Injectors (3) can only be removed in pairs (cylinder 1 and 2 or 3 and 4) with bracket (2) •   Remove 4x seal ring (arrows) •   Seal 4x injector with protective cap

  Install

5.   Clean 4x injector seat with EN-47632 •   Loosen dirt with the brush side (1) •   Remove dirt with the sponge side (2)

6.   Install 4x injector •   Replace 4x injector shaft seal ring •   Replace 4x injector seal ring (1) •   Tighten 2x nut 20 Nm

9.	Install fuel high pressure lines, accumulator - injector