Replacing Injection Valves Opel Astra H

Spezialwerkzeugliste:

KM-6326-1 KM-6359 KM-6360 KM-6364 KM-796-A KM-807 KM-J-34730-91

Note. When working on the fuel system, cleanliness must be strictly observed as even small particles of dirt can lead to faults in the engine or fuel system. The injectors may only be removed with the engine cold and with unequivocal diagnosis.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach earth cable – Slacken nut
3. 3. Remove engine cover
4. 4. Remove air intake pipe (2) • Undo 2x clamps (1)

5. 5. Detach engine vent valve • Undo 2 clamps • Unclip engine vent

6. 6. Remove engine control unit
7. 7. Remove wiring harness for engine management • Release and disconnect 2x wiring harness plug – Fuel pressure sensor (high pressure), fuel pressure regulator (high pressure) • Undo cable tie

Note. Wiring harness plug is disconnected if injectors remain in cylinder head

8. 8. Release fuel pressure Warning: Comply with safety regulations and national legislation. • Use KM-J-34730-91 • Unscrew protective cap from test connection • From fuel line

9. 9. Detach fuel line (1) • Use KM-796-A • Unclip fuel line • Seal fuel line and fuel rail – Use KM-807
10. 10. Remove fuel connection line (2) • Use KM-796-A • Unclip fuel line • Seal fuel line, fuel rail and high pressure fuel pump – Use KM-807
11. 11. Detach high pressure fuel line (3) Warning: Collect emerging fuel. • Unscrew 2x union nuts • High pressure pump, fuel rail – Use KM-6326-1

12. 12. Detach wiring harness bracket • Unscrew 2x nuts • Release and disconnect 3x wiring harness plug – Tank vent valve, intake pipe pressure sensor, channel switch control motor • Unclip wiring harness
13. 13. Undo fuel rail • Detach bracket – Unscrew 2x stud bolt (1) • Unscrew 4x bolts (2)

14. 14. Remove fuel rail • Use KM-6359

Note. In the case of injectors located in the cylinder head, remove injectors from cylinder head (using KM-6360 ).

Important. Do not jam fuel rail when pressing it off.

15. 15. Detach KM-6359

16. 16. Detach injector wiring harness
17. 17. Detach fuel injector • Detach spring clamp, retaining clamp (plastic) • Clean valve body

Important. Only injector nozzles with the same part numbers are to be incorporated.

Important. Use a soft brass brush. Brush with brass brush in one direction only. Do not touch injector outlet.

Install

18. 18. Replace 4x combustion chamber seal ring (1) • Cut combustion chamber seal ring • Pull open combustion chamber seal ring (1) on slip-on drift – Replace sealing ring

Important. Do not damage metal surface.

Note. Place slip-on drift on injector and push combustion chamber seal ring with cylindrical side of mounting sleeve KM-6364 onto injector up to the groove. Smooth combustion chamber seal ring with conical side of mounting sleeve by lightly turning. Leave mounting sleeve attached.

19. 19. Replace injector seal ring • Detach seal ring • Detach thrust ring • Clean 4x sealing surfaces • Fit thrust ring using slip-on drift – Replace thrust ring • Attach seal ring – Replace sealing ring

Note. To protect the injector outlet and condition the combustion chamber seal ring, KM-6364 remains attached until immediately before installation in the fuel rail.

20. 20. Attach fuel injector • Attach spring clip – Replace spring clip • Attach retaining clamp (plastic) – Replace retaining clamp

Note. Press in injector with circling movements. Do not use lubricant, must be easy to fit.

Note. Spring clip must audibly engage.

21. 21. Attach injector wiring harness • Connect and lock 6x wiring harness plug – 4x injector, fuel pressure sensor (high pressure), fuel pressure regulator (high pressure)
22. 22. Install fuel rail • Clean contact surface in cylinder head using compressed air • Carefully insert fuel injectors • Detach 4x KM-6364 • Tighten 4x bolt 4 Nm + 8 Nm • Attach bracket – Align retaining shackles • Tighten 2 stud bolts 8 Nm • Tighten 2x bolt 8 Nm

Important. The bolts must be tightened twice according to the tightening sequence. Tighten bolts from inside to outside.

23. 23. Install wiring harness bracket • Tighten 2x nuts • Connect and lock 3x wiring harness plug – Tank vent valve, intake pipe pressure sensor, channel switch control motor • Attach wiring harness
24. 24. Attach high-pressure fuel line • Clean connections • Remove KM-6326-1 • Tighten 2x union nuts 25 Nm
25. 25. Attach fuel connection line • Clean connections • Remove KM-807
26. 26. Attach fuel line • Clean connections • Remove KM-807 • Clip in line
27. 27. Attach wiring harness for engine management • Connect and lock combination plug • Attach wiring harness
28. 28. Attach engine vent • Clip in engine vent • Attach 2x clamps
29. 29. Attach engine control unit
30. 30. Install air intake pipe. • Tighten 2x clamp 3.5 Nm
31. 31. Attach engine cover
32. 32. Connect battery
33. 33. Fuel System, Check for Leaks • Start engine.

Important. Wear protective goggles and protective gloves.

Note. Check fuel system for escaping fuel.

34. 34. Close bonnet
35. 35. Program volatile memories