Vauxhall Workshop Service and Repair Manuals

J492900 Fuel Injection Lines, Replace (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 air intake pipe Remove 3 bolts Remove vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger 5. Remove charge air hose From turbocharger, centre charge air pipe Release 2 clamps

6. Remove wiring harness plug for engine control unit 3 off Release 2 wiring harness plugs in direction of arrow

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

8. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness (arrows) 9. Detach starter/alternator wiring harness bracket From exhaust recirculation valve Remove 2 nuts 10. Remove centre charge air pipe Unscrew studs, 3 bolts

11. Remove exhaust recirculation valve (1) Remove exhaust recirculation pipe Remove 2 bolts Unscrew studs (3), 2 bolts (arrows) Detach vacuum hose (2) Remove gaskets 12. Detach sheathed glow plug wiring harness plugs 4 off

13. Remove oil filter element Place collecting basin underneath. Unscrew oil filter housing cover (1) 14. Detach oil filter housing cover return hose Release clamp

15. Remove injection line spacers (1) Note! Mark spacer positions Remove 3 bolts 16. Remove injection lines With KM-6098 4 off 17. Install injection lines Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump. Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

18. Install injection line spacers

• Note! Observe spacer positions. Transfer marks from removed injection lines.

19. Install oil filter housing cover return hose

• Fasten clamp

20. Install oil filter element

• Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)
• Replace seal ring

21. Attach engine transport shackles

• Tighten bolts (20 Nm / 15 lbf. ft.)

22. Install exhaust recirculation valve

• Clean sealing surfaces.
• Insert exhaust recirculation valve
• Tighten studs, bolts (24.5 Nm/18.1 lbf. ft.)
• Replace gaskets
• Connect vacuum hose.
• Attach exhaust gas recirculation pipe
• Tighten bolts (28.4 Nm / 20.9 lbf. ft.)
• Replace gasket

23. Install centre charge air pipe

• Clean sealing surface
• Tighten studs, bolts
• Replace gasket

24. Attach starter/alternator wiring harness bracket

• To exhaust recirculation valve
• Tighten nuts

25. Install sheathed glow plug wiring harness plugs

• Route wiring harness
• Connect wiring harness plug.

26. Install engine control unit bracket

• Tighten bolts (24.5 Nm/18.1 lbf. ft.)
• Tighten nut (9.8 Nm/7.2 lbf. ft.)
• Attach wiring harness

27. Install engine control unit

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

28. Install air intake pipe

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

29. Attach charge air hose

• Install clamps

30. Attach engine control unit wiring harness plug

• 3 off

31. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Fasten clamp
• 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. Top up engine oil

• Observe specified engine oil quantity
• Start engine and allow to run until oil pressure telltale extinguishes.
• Check engine oil level, if necessary correct.

35. Program volatile memories

36. Close bonnet