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How to Replace the Injectors Opel Meriva A

Fuel Injection Systems 6 illustrations ~440 words

Warning: When working on the Common Rail System, please wait for one minute after switching the engine off. The system relieves the pressure automatically.

Important: When working with fuel systems, cleanliness must be ensured at all times since even the smallest dirt particles can lead to disruptions of engine operation or in the fuel system. Plug open fuel fittings with suitable sealing plugs. 1) Sealing plugs are intended for single use only.

Note. Injectors can also be replaced individually. If one or all of the injectors are replaced, the IMA code of the injectors must be programmed into the engine control unit using TECH 2.

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery • Detach ground clamp from ground terminal – Undo nut
  3. 3. Remove air intake manifold • Unscrew 2x bolt • Unclip 3x wiring harnesses • Detach engine vent hose – Disconnect quick-release fitting • Detach from air intake manifold – Release clamp • Detach from turbocharger – Release clamp
  4. 4. Place collecting basin underneath
  5. 5. Detach 4x oil leak lines • Release 4x retaining clamps (1) in direction of arrow

Note. Retaining clamps are not removed

  1. 6. Remove 4x high pressure lines (1) • Unscrew 8x union nut
  1. 7. Disconnect 4x injector wiring harness plugs (1)
  1. 8. Remove 4x injectors (3) • Detach 2x brackets (2) – Unscrew 2 nuts (1) • Remove 4x seal rings (arrows) • Seal 4x injectors with protective caps

Note. Injectors (3) can only be removed in pairs (no.1 and no.2 cylinders or no.3 and no.4 cylinders) with brackets (2)

Install

  1. 9. Clean 4x injector seats with EN-47632 • Remove soiling with brush side (1) • Remove soiling with sponge side (2)
  1. 10. Install 4x injectors • Replace 4x injector shaft seal rings • Renew 4x injector seal rings (1) • Tighten 2x nut 20 Nm
  1. 11. Install 4x new high pressure lines • Tighten 4x union nuts (M14) 28 Nm • Tighten 4x union nuts (M12) 24 Nm
  2. 12. Attach 4x oil leak lines • Release 4x retaining clamps
  3. 13. Connect 4 injector wiring harness plugs
  4. 14. Install air intake manifold • Attach to turbocharger – Tighten clamp 3.5 Nm • Attach to air intake manifold – Tighten clamp 3.5 Nm • Tighten 2 bolts • Attach engine vent hose – Fasten clamp • Clip in 3x wiring harnesses
  5. 15. Connect battery • Attach ground clamp to ground terminal – Tighten nut
  6. 16. Calibrate steering angle sensor • Switch ignition on

Note. Turn steering wheel once from right stop to left stop.

  1. 17. Program volatile memory

1

) Protective caps can be ordered from the parts catalogue

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