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Home/Opel/Agila/Opel Agila B (2008-2011)/Repair manual/Engine Control and Fuel System - D13A/One Fuel Injector Replacement
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One Fuel Injector Replacement Opel Agila B

Engine Control and Fuel System - D13A 9 illustrations ~491 words

Remove

  1. 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. 2. Disconnect battery negative lead • Release nut
  3. 3. Remove engine cover (1) from engine • Remove 4x bolt
  1. 4. Remove engine cover bracket and camshaft cover insulation (1) from engine • Remove 2x bolt (2)
  1. 5. Remove intercooler outlet pipe (2) from engine • Release clip (1) • Remove 5x bolt
  1. 6. Release 4x fuel injector feed pipe (1, 2) from high pressure pump and fuel injector • Unscrew 8x union nut
  2. 7. Remove 4x fuel injector feed pipe • Install 8x blanking plug
  3. 8. Disconnect fuel leak back pipe from fuel return pipe • Release clip (3)
  1. 9. Disconnect 4x wiring harness plugs for injector (1)
  1. 10. Remove fuel leak back pipe (1) from 4x injector • Unlock 4x retaining clamps (2) in direction of arrow • Install 4x blanking plug
  1. 11. Remove 4x injector (2) • Detach 2x bracket (3) – Unscrew 2x nuts (1) • Remove 4x seal ring • Seal 4x injector with protective cap

Note. Injectors (2) can only be removed in pairs (cylinder 1 and 2, or 3 and 4) with bracket (3)

Install

  1. 12. Clean 4x injector seat with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)
  1. 13. Install new 4x injector (2), 4x washer, 2x clamp (3) • Replace 4x injector shaft seal ring • Replace 4x injector seal ring • Tighten 2x nut (1) 23 Nm
  1. 14. Install leak back pipe (1) to 4x injector • Remove 8x blanking plug • Secure 4x clip (2)
  1. 15. 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
  2. 16. Secure 4x fuel injector fuel feed pipe (1, 2) to 4x fuel injector • Secure 4x pipe union 27 Nm
  3. 17. Secure 2x fuel injector fuel feed pipe (1) to fuel injection fuel rail assembly • Secure 2x pipe union 29 Nm
  4. 18. Secure 2x fuel injector fuel feed pipe (2) to fuel injection fuel rail assembly • Secure 2x pipe union 32 Nm
  5. 19. Connect leak back pipe to fuel return pipe • Secure clip (3)
  1. 20. Connect 4x wiring harness plugs to injector (1)
  1. 21. Install intercooler outlet pipe (2) to engine • Secure clip (1) • Secure 5x bolt 11 Nm
  1. 22. Install engine cover bracket and cylinder head cover insulation (1) to engine • Install 2x bolt (2) 11 Nm
  1. 23. Install engine cover (1) to engine • Install 4x bolt 8 Nm
  1. 24. Connect battery negative lead • Secure nut 11 Nm
  2. 25. Program all volatile memories – see operation “Program Volatile Memories”

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