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Engine Coolant Temperature Sensor Replacement > < Exhaust Gas Recirculation Valve Actuator Replacement

Astra J

Fuel Injector Replacement

Special Tools

•  DT-328-B   Pin Remover
•  EN-46786   Remover
•  EN-47632   Cleaning Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .
Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.



Note: 
•  Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal. Store the components so that contaminants cannot enter.
•  In order to reuse the injectors, mark the injectors so that they can be installed to the same cylinder

1. Open the Hood
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

Note:  Wait 60 sec. after engine shutdown before opening the high pressure fuel system.
3. Remove the 4 fuel injection fuel feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement - Right Side .

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4. Remove the 2 engine sight shield holding studs (1).
5. Disconnect the 4 electrical connections (2) and hang the wiring harness aside.

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6. Remove the 4 injector bracket nuts (1) in conjunction with the 4 washers (2).
7. Remove the 4 injector brackets (3).

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8. Install EN-46786   remover (2) to the injector (3) in conjunction with DT-328-B   remover (1) in order to remove the fuel injector.

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9. Remove the 4 Injectors (1).

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10. Clean the injector sealing surfaces in the cylinder head using EN-47632   cleaning tool (1) in following procedure:
  •  First take the brush side to loosen the dirt.
  •  Second take the sponge side to remove the dirt.

Installation Procedure


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1. Install the 4 Injector (1) along with a NEW gasket.

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2. Install the 4 injector brackets (3).
3. Install the 4 washers (2).
4. Loosely install the 4 injector bracket nuts (1).

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5. Install the 4 fuel injection fuel feed pipes (3).
6. Loosely install the 8 fuel injection fuel feed pipe nuts (2, 1).

Caution: Refer to Fastener Caution .

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7. Bring the 4 fuel injection nuts (1) to the right torque and tighten to 25 N·m (18 lb ft) .
8. Bring the 4 fuel injection fuel feed pipe nuts to fuel injectors to the right torque and tighten to 25 N·m (18 lb ft) .
9. Bring the 4 fuel injection fuel feed pipe nuts to fuel rail to the right torque and tighten to 19 N·m (14 lb ft) .

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10. Connect the 4 electrical connections (2).
11. Install the 2 engine sight shield holding studs (1) and tighten.
12. If new injectors are installed, use the diagnostic tool for programming.
13. Check that the fuel system is not leaking after the engine was running. Connect the diagnostic tool and erase any diagnostic trouble codes.
14. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Close the hood.

Engine Coolant Temperature Sensor Replacement > < Exhaust Gas Recirculation Valve Actuator Replacement