Attention! It is important to maintain extreme cleanliness when working on the fuel system, as even tiny particles of dirt can cause the system or engine to operate abnormally. The fuel system fittings must be closed with suitable plugs (according to the Opel parts catalog number 45 06 154 / part number: 9201697). The sealing plugs are disposable.
Removing
Open the hood.
Disconnect the battery.
Disconnect the ground connector from the ground clamp by loosening the fastening nut.
Remove the engine cover.
Note. Reattach the rubber mounts, which may have come loose during removal, to the engine cover.
Attention! After disconnecting the high pressure pipes, close the openings of the fuel injector and pressure chamber with protective covers.
Remove 4 high pressure pipes.
Attention! When loosening the lock nut, hold the injector with an open wrench.
Remove 8 lock nuts.
Disconnect the oil line (pic. 2.268).
Note. The oil line cannot be disconnected from the fuel return damping housing.
Remove 4 clamps (arrows in the picture).
Remove the oil line.
Remove 4 fuel injectors by unscrewing 4 mounting nuts.
Note. If fuel injectors cannot be removed by hand, use special tool B 46786 in conjunction with KM-328-B.
Installation
Clean the 4 fuel injector covers.
Note. To clean the fuel injector seats, install B 47632 coarse wool into the fuel injector housing and clean the fuel injector seat. Repeat the cleaning process with clean wool.
Install 4 fuel injectors.
Replace 4 O-rings.
Install 4 fuel injectors with bracket.
Note. Installation sequence - cylinder 4, 3, 2, 1.
Tighten 4 nuts to 25 Nm.
Connect the oil line.
Connect 4 oil lines to the fuel injectors.
Attention! When tightening the lock nut, hold the fuel injector with an open wrench. Discharge pipelines can only be connected only once.
Install 4 new high pressure lines.
Tighten 4 lock nuts (M12) torque 25 Nm.
Tighten 4 lock nuts (M14) torque 23 Nm.
Connect the battery.
Connect the ground connector to the ground terminal. Tighten the nut.
Check fuel system for leaks.
Attention! Wear safety goggles and protective gloves before checking.
Start the engine.
Install the engine cover.
Program the volatile memory.
Close the hood.
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