Fuel Injection Fuel Rail Assembly Replacement — Engine — Engine Control and Fuel System - D13A

Fuel Injection Fuel Rail Assembly Replacement Opel Agila B

1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. Disconnect battery negative lead • Release nut
3. Remove engine cover (1) from engine • Remove 4x bolt

4. Remove engine cover bracket and camshaft cover insulation (1) from engine • Remove 2x bolt (2)

5. Remove intercooler outlet pipe (2) from engine • Release clip (1) • Remove 5x bolt

6. Remove intermediate pipe (3) from high pressure fuel pump and fuel injection fuel rail assembly • Release 2x pipe union • Install 4x new blanking plug
7. Remove 4x fuel injector fuel feed pipe (1, 2) from fuel injection fuel rail assembly and 4x fuel injector • Release 8x pipe union • Install 16x new blanking plug
8. Remove fuel injection fuel rail assembly from bracket • Remove 2x bolt • Disconnect harness connector from fuel rail pressure sensor • Disconnect harness connector from fuel rail pressure regulator
9. Disconnect leak back pipe from fuel return pipe • Release clip (4)

10. Install fuel injection fuel rail assembly to bracket • Install 2x bolt; do not tighten at this stage
11. Install 4x new fuel injector fuel feed pipe (1, 2) to fuel injection fuel rail assembly and 4x fuel injector • Remove 16x blanking plug • Install 8x pipe union; do not tighten at this stage
12. Install new intermediate pipe (3) to high pressure fuel pump and fuel injection fuel rail assembly • Remove 4x blanking plug • Install 2x pipe union; do not tighten at this stage
13. Secure fuel injection fuel rail assembly to bracket • Secure 2x bolt 85 Nm
14. Secure 4x fuel injector fuel feed pipe (1, 2) to 4x fuel injector • Secure 4x pipe union 27 Nm
15. Secure 2x fuel injector fuel feed pipe (1) to fuel injection fuel rail assembly • Secure 2x pipe union 29 Nm
16. Secure 2x fuel injector fuel feed pipe (2) to fuel injection fuel rail assembly • Secure 2x pipe union 32 Nm
17. Secure intermediate pipe (3) to high pressure fuel pump • Secure pipe union 27 Nm
18. Secure intermediate pipe (3) to fuel injection fuel rail assembly • Secure pipe union 32 Nm
19. Connect leak back pipe to fuel return pipe • Secure clip (4)
20. Connect harness connector to fuel rail pressure regulator
21. Connect harness connector to fuel rail pressure sensor

22. Install intercooler outlet pipe (2) to engine • Secure clip (1) • Secure 5x bolt 11 Nm

23. Install engine cover bracket and cylinder head cover insulation (1) to engine • Install 2x bolt (2) 11 Nm

Fuel Injection Fuel Rail Assembly Replacement Opel Agila B