Important: When working on the fuel system maintaining cleanliness is essential, otherwise the smallest particles of dirt may result in engine operating faults or faults in the fuel system. 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 injector or all of them, the IMA code of the injectors must be programmed into the engine control device using TECH 2
Remove
- 1. Open bonnet
- 2. Remove engine cover. • 4x unclip
Note. Rubber brackets must be left on the engine cover
- 3. Disconnect battery. • Detach ground clamp from ground terminal – Remove nut
- 4. Disconnect wiring harness plug for injector
- 5. Detach oil leak line (1) • Press retaining clamp in the direction of the arrow • Detach oil leak line and lay aside
- 6. Remove engine vent pipe (2) when replacing injector for cylinder 1 • Detach hose (3) – Release clamp • Open 2x wiring harness clip – Lay wiring harness aside • Unscrew 2x bolt (1)
- 7. Remove high pressure line 1 (1) when replacing injector for cylinder 1 • Unscrew 2x union nut • Close off any connections with suitable stoppers
Important. When releasing the union nut at injector, counterhold with open-ended wrench
- 8. Remove 2x high pressure line when replacing injector for cylinder 2, 3 or 4 • Remove high pressure line of cylinder concerned (2) – Unscrew 2x union nut – Close off any connections with suitable stoppers • Remove high pressure line of the cylinder directly on the left (seen from the front) (1) – Unscrew 2x union nut – Close off any connections with suitable stoppers
Important. When releasing the union nut at injector, counterhold with open-ended wrench
Important. When releasing the union nut at injector, counterhold with open-ended wrench
- 9. Remove stud bolts • Unscrew nut • Screw on 2x counter nut (1) • Unscrew stud bolt
- 10. Remove injector • Pull out injector • Remove injector with bracket • Remove Seal ring • Close off any connections with suitable stoppers
Note. If the injector cannot be removed by hand, use KM-328-B in connection with EN-46786 (1)
Install
- 11. Cleaning work
Note. Use EN-47632 to clean the injector seats. Insert EN-47632 in the injector shaft with coarse fleece and pre-clean the injector seat by turning. Then perform final cleaning with fine fleece.
- 12. Install injector • Remove sealing plug • Replace seal ring • Insert injector with bracket
- 13. Install stud bolt • Tighten stud bolts 14 Nm • Unscrew 2x counter nut
- 14. Fasten injector • Tighten new nut 25 Nm
- 15. Install 2x high pressure line when replacing injector for cylinder 2, 3 or 4 • Install new high pressure line of cylinder concerned – Remove sealing plug – Tighten lock nut (M12) 25 Nm – Tighten lock nut (M14) 23 Nm • Install new high pressure line of the cylinder directly on the left (seen from the front) – Remove sealing plug – Tighten lock nut (M12) 25 Nm – Tighten lock nut (M14) 23 Nm
Important. When securing the lock nut, counterhold at injector with open-ended wrench
Important. When securing the lock nut, counterhold at injector with open-ended wrench
- 16. Install new high pressure line 1 when replacing injector for cylinder 1 • Remove sealing plug • Tighten lock nut (M12) 25 Nm • Tighten lock nut (M14) 23 Nm
Important. When securing the lock nut, counterhold at injector with open-ended wrench
- 17. Install engine vent pipe when replacing injector for cylinder 1 • Attach hose – Fasten clamp • Clip in 2x wiring harness • Tighten 2x bolts 9 Nm
- 18. Attach oil leak line • Retaining clamp must engage audibly
- 19. Connect injector wiring harness plug
- 20. Connect battery. • Attach ground clamp to ground terminal – Tighten nuts
- 21. Program volatile memories
- 22. Install engine cover. • Clip in 4x
- 23. Close bonnet