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Contents Wiring diagrams Section: Fuel Injection Systems All sections

How to Replace the Injectors Opel Agila A

Fuel Injection Systems 6 illustrations ~371 words

Warning: When working with the common rail system, wait one minute after switching off the engine. The system relieves the pressure itself.

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

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

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery • Detach ground clamp from ground terminal – Loosen nut
  3. 3. Remove air cleaner housing
  4. 4. Disconnect 4 injector wiring harness plugs (1)
  1. 5. Detach leak oil line • from injectors – Unlatch 4x retaining clamps (1) in the direction of the arrow • from pressure chamber

Note. Retaining clamps are not detached

  1. 6. Detach 4x high pressure line (1) from the injector pressure chamber • Unscrew 8 union nuts
  1. 7. Remove 4 injectors (3) • Detach 2 brackets (2) – Unscrew 2x nut (1) • Remove 4 seal rings (arrows) • Seal 4 injectors with protective caps

Note. Injectors (3) can only be removed with bracket (2) in pairs (1st/2nd cylinder and 3rd/4th cylinder)

Install

  1. 8. Clean 4 injectors with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)
  1. 9. Install 4 injectors • Replace 4 injector shaft seal rings • Replace 4 injector seal rings (1) • Tighten 2 nuts 20 Nm
  1. 10. Install 4 high pressure lines, pressure chamber to injector • Tighten 4x union nut (M14) 28 Nm • Tighten 4x union nut M12 24 Nm

Note. Use new high pressure lines

  1. 11. Connect 4 injector wiring harness plugs
  2. 12. Attach oil leak hose • Release 4 retaining clamps
  3. 13. Install air cleaner housing
  4. 14. Connect battery • Attach ground clamp to ground terminal – Tighten nut 5.5 Nm
  5. 15. Program volatile memories
  6. 16. Close bonnet.

1

) Protective caps are available in the Opel Parts Catalogue under catalogue number: 45 06 154 / part number: 9201697

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