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Exhaust Gas Recirculation Valve Cooler Replacement - 1.7L Diesel LPL, LPV, LUD, and LUE > < Fuel Tank Filler Hose Replacement

Astra J

Fuel Injector Replacement

Special Tools

•  EN-47632   Cleaning Tool
•  EN-48560   Injector Fixing Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
3. Remove the camshaft cover. Refer to Camshaft Cover Replacement .

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4. Remove the 4 fuel injector bolts (2) in conjunction with the 4 washers (3).
5. Remove the 4 fuel injector brackets (4).

Note:  The fuel injector gaskets has to be replaced every time the injector was removed.
6. Remove the 4 fuel injectors (1) in conjunction with the 4 fuel injector gaskets (5).

Installation Procedure


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Note:  Use both sides of EN-47632   cleaning tool , one for loosening the dirt and the other to haul out the dirt.
1. Clean the sealing surface, using the EN-47632   cleaning tool (1).

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2. Install the 4 fuel injectors (1) in conjunction with the 4 NEW fuel injector gaskets (5).
3. Install the 4 fuel injector brackets (4).
4. Loosely install the 4 fuel injector bolts (2) in conjunction with the 4 washers (3).

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5. Install the EN-48560   fixing tool (1) in order to fix the injectors.

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Note:  Do not remove the fuel rail (1).
6. Loosen the fuel rail bolt (2).

Caution: Refer to Fastener Caution .

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7. Install the 4 fuel injection fuel feed pipes (3) to the fuel rail (2) and to the fuel injectors (1) and hand tighten.

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8. Tighten the 4 fuel injector bolts (2) in sequence:
  •  First step: tighten to 40 N·m (30 lb ft) .
  •  Second step: loosen the 4 fuel injector bolts (2).
  •  Third step: tighten to 32 N·m (24 lb ft) .

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9. Fasten the fuel rail (1) by tighten the 2 fuel rail bolts (2) to 25 N·m (18 lb ft) .
10. Remove the 4 fuel feed pipes.

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11. Remove the EN-48560   fixing tool (1).
12. Install the camshaft cover. Refer to Camshaft Cover Replacement .
13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
14. After the replacement of the fuel injectors, use a scan tool for programing the fuel injector flow rate. Refer to Fuel Injector Flow Rate Programming and for configuration and set up information, refer to Engine Control Module Programming and Setup .
15. Close the hood.

Exhaust Gas Recirculation Valve Cooler Replacement - 1.7L Diesel LPL, LPV, LUD, and LUE > < Fuel Tank Filler Hose Replacement