Multec-S Injection System Components; Inlet Air Temperature Sensor; Fuel Injectors And Fuel Rail; Crankshaft Speed/Position Sensor - Opel Zafira B MPV 2006 Owners Workshop Manual

4A•8 Fuel and exhaust systems - petrol engines
be interrogated, and any stored fault codes
can be retrieved. This will allow the fault to be
quickly and simply traced, alleviating the need
to test all the system components individually,
which is a time-consuming operation that
carries a risk of damaging the ECU.
Inlet air temperature sensor
Removal
1 Disconnect the wiring connector from the
inlet air temperature sensor at the right-hand
rear corner of the engine compartment (see
illustration 2.1).
2 On Z16XEP engines, slacken the retaining
clamps and remove the inlet air temperature
sensor from the air intake ducts. On Z16XE1
engines, pull the sensor out of the grommet in
the air cleaner intake duct.
Refitting
3 Refitting is a reversal of removal.
Fuel injectors and fuel rail
Note: Refer to the precautions given in Sec-
tion 1 before proceeding. The
seals
at both
ends of the fuel injectors must be renewed on
refitting.
Removal
4 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
5 Remove the air cleaner assembly and air
intake duct as described in Section 2.
6 Depressurise the fuel system as described
in Section 5.
7 Disconnect the fuel feed hose quick-release
connector at the fuel rail. Be prepared for
some loss of fuel. A Vauxhall/Opel special
tool is availablf;l to release the connector, but
provided care is taken, it can be released
using a pair of long-nosed pliers, or a similar
tool, to depress the retaining tangs. Clamp or
plug the open end of the hose, to prevent dirt
ingress and further fuel spillage.
8 Lift up the locking bars and disconnect the
two wiring connectors from the ECU.
9 Disconnect the wiring connector from the
throttle housing.
10 Undo the bolt securing the earth lead
to the top of the ECU, then undo the three
retaining bolts and remove the ECU from the
intake manifold.
11 Disconnect the wiring connector from the
manifold pressure sensor on the side of the
intake manifold.
12 Release the two clips and move the wiring
harness clear of the fuel rail.
13 Disconnect the wiring connector from
each fuel injector.
14 Unscrew the two mounting bolts, then lift
the fuel rail complete with the injectors off of
the intake manifold.
15 To remove an injector from the fuel rail,
prise out the metal securing clip using a
screwdriver or a pair of pliers, and pull the
injector from the fuel rail. Remove and discard
the injector sealing rings; new ones must be
fitted on refitting.
16 Overhaul of the fuel injectors is not
possible, as no spares are available. If faulty,
an injector must be renewed.
Refitting
17 Before refitting, clean thoroughly the
mating surfaces of the throttle housing and
intake manifold.
18 Commence refitting by fitting new 0-ring
seals to both ends of the fuel injectors. Coat
the seals with a thin layer of petroleum jelly
before fitting.
19 Refitting is a reversal of removal, bearing
in mind the following points:
a) When refitting the injectors to the fuel rail,
note that the groove in the metal securing
clip must engage with the lug on the
injector body.
b) Make sure that the quick-release
connector audibly engages on the fuel
rail.
c) Ensure that all wiring connectors are
securely reconnected, and that the
wiring
is
secured in the relevant clips and
brackets.
Crankshat't speed/
position sensor
Note: A new 0-ring seal must be used on
refitting.
Removal
20 The crankshaft sensor is mounted on the
front of the cylinder block below the oil filter.
21 Firmly apply the handbrake, then jack up
the front of the car and support it securely on
axle stands (see Jacking and vehicle support).
22 Disconnect the wiring connector, then
unscrew the retaining bolt and remove the
sensor from the front of the cylinder block.
Discard the sealing ring, a new one should be
used on refitting.
Refitting
23 Refitting is a reversal of removal using a
new sealing ring and tightening the sensor
bolt to the specified torque.
Camshat't sensor
Removal
24 The camshaft position sensor is located
behind the timing belt rear cover, on the
exhaust camshaft side.
25 Remove the air cleaner assembly and
intake duct as described in Section 2.
26 Undo the two retaining bolts then unclip
and remove the timing belt upper cover from
the rear cover.
27 Disconnect the camshaft sensor wiring
connector.
28 Using a spanner or socket on the crank-
shaft pulley retaining bolt, turn the crankshaft
until the camshaft sensor retaining bolt is
accessible through the spokes in the exhaust
camshaft sprocket.
29 Undo the sensor retaining bolt, then turn
the sensor and remove it from the rear of the
timing belt cover.
Refitting
30 Refitting is a reversal of removal, tightening
the sensor retaining bolt to the specified
torque.
Coolant temperature sensor
31 Refer to Chapter 3 for removal and refitting
details.
Manifold pressure sensor
Removal
32 On Z16XEP engines, remove the engine
management ECU as described later in this
Section. On Z16XE1 engines, remove the
throttle housing as described in Section 9.
33 Disconnect the pressure sensor wiring
connector.
34 Undo the sensor retaining bolt, then
remove the sensor from the intake manifold.
Refitting
35 Refitting is a reversal of removal, tightening
the sensor retaining bolt to the specified torque.
Knock sensor
Removal
36 The knock sensor is located on the rear
of the cylinder block, just above the starter
motor.
37 Apply the handbrake, then jack up the
front of the vehicle and support it on axle
stands (see Jacking and vehicle support).
38 Release the vacuum hose from the intake
manifold support bracket, then undo the two
bolts and remove the support bracket from
the cylinder block and manifold.
39 Disconnect the wiring connector from the
knock sensor.
40 Note its position, then unscrew the bolt
and remove the knock sensor from the block.
Refitting
41 Clean the contact surfaces of the sensor
and block. Also clean the threads of the
sensor mounting bolt.
42 Locate the sensor on the block and insert
the mounting bolt. Position the sensor as
previously noted, then tighten the bolt to the
specified torque. Note that the torque setting
is critical for the sensor to function correctly.
43 Refit the intake manifold support bracket
and attach the vacuum hose, then lower the
vehicle to the ground.
Electronic.control unit (ECU)
Note: If a new ECU is to be fitted, this work
must be entrusted to a Vauxha/1/0pel dealer or
suitably-equipped specialist
as
it
is
necessary
to programme the new ECU after installation.
This work requires the use of dedicated
Vauxhall/Opel diagnostic equipment or a
compatible alternative.