Vauxhall Workshop Service and Repair Manuals

Injectors, Remove and Install  

  Remove, Disconnect   

Disconnect wiring harness plug (1) from intake air temperature sensor and wiring harness plug (2) from hot film mass air flow meter. Disconnect engine vent hoses (3) from cylinder head cover. Disconnect air intake hose (4) from throttle body and air filter housing upper part.   Connect Fuel Pressure Gauge KM-J-34730-91 to test connection on fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge - collect escaping fuel in suitable container. Observe safety precautions and national regulations.   Disconnect fuel return line (5) from fuel pressure regulator and Bowden cable bracket. Disconnect wiring harness plug (6) from idle speed stepper motor.   Remove retainer for accelerator Bowden cable (7) and unclip accelerator Bowden cable from ball head.   If available: Remove retaining clip for cruise control Bowden cable and remove cruise control Bowden cable from ball head.   Remove Bowden cable bracket (8) from throttle body and lay aside with Bowden cables to the rear.

  Remove, Disconnect   

Press retaining clip for 1st cylinder and 4th cylinder injectors (arrows) in plug strip (with screwdriver) away from engine side, pull plug strip (1) upwards and place to one side.   Remove fastening pin (2) and fastening bolt (3).   Carefully pull fuel distributor pipe together with injectors out of intake manifold.

  Remove, Disconnect   

Remove relevant spring clips (1) and pull injector from fuel distributor pipe.     Install, Connect    Attach new seal rings to injectors and lightly coat with clean engine oil. Insert injector carefully into fuel distributor pipe and secure with spring clip (1).     Important!    The positions of the spring clips for the injection valves only allow the plug strip to engage in a certain position. Align all spring clips so that correct contact of the plug strip to the injection valves is ensured.     Install, Connect    Carefully insert fuel distributor pipe together with injectors into intake manifold and attach to intake manifold using fastening pin and fastening bolt - tightening torque 8 Nm / 6 lbf. ft.   Connect plug strip to injectors - ensure correct seating, plug strip must engage audibly.

  Install, Connect   

Connect Bowden cable bracket to throttle body and connect Bowden cables to ball head and secure.  

Connect wiring harness plug to idle speed stepper motor.  

Connect fuel return line to fuel pressure regulator and Bowden cable bracket - tightening torque 15 Nm / 11.1 lbf. ft.  

Notice: 

Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.  

  Important!   

It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.  

  Install, Connect   

Attach air intake hose to throttle body and upper part of air cleaner housing.  

Attach engine vent hoses to cylinder head cover.  

Connect wiring harness plugs to intake air temperature sensor and to hot film mass air flow meter.