Important: When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.
Note. Injectors can also be replaced individually. When replacing one or all the injectors, the IMA code of the injectors must be programmed in using TECH 2 in the engine control unit
Remove
- 1. Remove engine cover
- 2. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
- 3. Disconnect wiring harness plug for injector
- 4. Detach leak oil line (1) • Press retaining clamp in direction of arrow • Detach oil leak line and set aside
- 5. When replacing the injector for cylinder 1: detach engine venting pipe (2) • Detach hose (3) – Release clamp • Open 2x wiring harness clips – Set wiring harness aside • Unscrew 2x bolts (1)
- 6. When replacing the injector for cylinder 1: remove high-pressure line for cylinder 1 (1) • Unscrew 2x union nuts • Seal off connections with suitable sealing plugs
Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector
- 7. When replacing the injector for cylinders 2, 3, or 4: remove 2x high-pressure lines • Remove high-pressure line of cylinder in question (2) – Unscrew 2x union nuts – Seal off connections with suitable sealing plugs • Remove high-pressure line of the neighbouring cylinder on the left (when viewed from the front) (1) – Unscrew 2x union nuts – Seal off connections with suitable sealing plugs
Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector
Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector
- 8. Remove stud bolt • Unscrew nut • Screw on 2x lock nuts (1) • Unscrew stud bolt
- 9. Remove injector • Pull out injector • Remove injector with bracket • Remove seal ring • Seal off connections with suitable sealing plugs
Note. If the injector cannot be removed by hand, use KM-328-B in conjunction with EN-46786 (1)
Install
- 10. Cleaning work
Note. Use EN-47632 to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and turn it to clean the injector seat. Finish by cleaning with fine fleece.
- 11. Install injector • Remove closure plug • Replace sealing ring • Insert injector with bracket
- 12. Install stud bolt • Tighten stud bolt 14 Nm • Unscrew 2x lock nuts
- 13. Fasten injector • Tighten new nut 25 Nm
- 14. When replacing the injector for cylinders 2, 3, or 4: install 2x new high-pressure lines • Install new high-pressure line of cylinder in question – Remove closure plug – Tighten retaining nut (M12) 25 Nm – Tighten union nut (M14) 23 Nm • Install new high-pressure line of the neighbouring cylinder on the left (when viewed from the front) – Remove closure plug – Tighten retaining nut (M12) 25 Nm – Tighten union nut (M14) 23 Nm
Important. When fastening the union nut, counterhold with open-ended wrench against the injector
Important. When fastening the union nut, counterhold with open-ended wrench against the injector
- 15. When replacing the injector for cylinder 1: install new high-pressure line for cylinder 1 • Remove closure plug • Tighten retaining nut (M12) 25 Nm • Tighten union nut (M14) 23 Nm
Important. When fastening the union nut, counterhold with open-ended wrench against the injector
- 16. When replacing the injector for cylinder 1: attach engine venting pipe • Attach hose – Fasten clamp • Clip in 2x wiring harnesses • Tighten 2x bolt 9 Nm
- 17. Attach oil leak line • Retaining clamp must audibly engage
- 18. Connect injector wiring harness plug
- 19. Connect battery • Attach ground connection to ground terminal – Tighten nut
- 20. Program volatile memories
- 21. Install engine cover