Fuel Injectors; Unscrew Union Nuts Securing High-Pressure Fuel Pipes To Fuel Rail; Unscrew Union Nuts Securing High-Pressure Fuel Pipe To Fuel Pump; Disconnect The Fuel Return Hose - Opel Zafira B MPV 2006 Owners Workshop Manual

17
Observing the precautions listed in
Section 2, prime the fuel system as described
in Section 5, then start the engine and allow it
to idle. Check for leaks at the high-pressure
fuel pipe unions with the engine idling. If
satisfactory, increase the engine speed to
4000 rpm and check again for leaks. If any
leaks are detected, obtain and fit a new
high-pressure fuel pipe(s).
18
Refit the windscreen cowl panel as
described in Chapter 11.
19 Refit the engine cover on completion.
DOHC (Z19DTHJ engines
Note: A complete new set of high-pressure
fuel pipes will be required for refitting.
Removal
20 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
21 Remove the windscreen cowl panel as
described in Chapter 11 .
22 Remove the plastic cover over the top of
the engine.
23
Thoroughly clean all the high-pressure
fuel pipe unions on the fuel rail, fuel pump
and injectors. Using two spanners, hold the
unions and unscrew the union nuts securing
the high-pressure fuel pipes to the fuel
injectors. Unscrew the union nuts securing
the high-pressure fuel pipes to the fuel rail,
withdraw the pipes and plug or cover the open
unions to prevent dirt entry (see illustration).
24 Using an open-ended spanner, unscrew
the union nuts securing the high-pressure
fuel pipe to the fuel pump and fuel rail (see
illustration). Counter-hold the unions on
the pump with a second spanner, while
unscrewing the union nuts. Withdraw the
high-pressure fuel pipe and plug or cover the
open unions to prevent dirt entry.
25 Disconnect the wiring connectors at
the fuel pressure regulator and fuel pressure
sensor, then release the clip and disconnect
the fuel return hose. Undo the two bolts and
remove the fuel rail (see illustrations).
Refitting
26 Refit the fuel rail and tighten the retaining
bolts to the specified torque. Reconnect the
fuel pressure regulator and fuel pressure
sensor wiring connectors, and reconnect the
fuel return hose.
27 Working on one fuel injector at a time,
remove the blanking plugs from the fuel pipe
unions on the fuel rail and the relevant injector.
Locate the new high-pressure fuel pipe over
the unions and screw on the union nuts finger
tight. Tighten the union nuts to the specified
torque using a torque wrench and crow-foot
adapter. Counter-hold the union on the injector
with an open-ended spanner, while tightening
the union nut. Repeat this operation for the
remaining three injectors.
28 Similarly, fit the new high-pressure
fuel pipe to the fuel pump and fuel rail, and
tighten the union nuts to the specified torque.
Counter-hold the union on the pump with an
Fuel and exhaust systems - diesel engines 48•9
13.23 Unscrew the union nuts securing the
high-pressure fuel pipes to the fuel rail and
injectors
open-ended spanner, while tightening the
union nut.
29 Reconnect the battery negative terminal.
30 Observing the precautions listed in
Section 2, prime the fuel system as described
in Section 5, then start the engine and allow it
to idle. Check for leaks at the high-pressure
fuel pipe unions with the engine idling. If
satisfactory, increase the engine speed to
4000 rpm and check again for leaks. If any
leaks are detected, obtain and fit a new
high-pressure fuel pipe(s).
31
Refit the windscreen cowl panel as
described in Chapter 11 .
32
Refit the engine cover on completion.
Warning: Refer to the information
contained in Section 2 before
proceeding.
SOHC (Z19DT and DTLJ engines
Note 1:
A new copper washer, retaining nut
and high-pressure fuel pipe will be required
for each removed injector when refitting.
Note 2: The injector is an extremely tight fit
in the cylinder head, and it is likely that the
special Vauxhall/Opel puller (KM-328-B) and
adapter (EN-46786) or suitable alternatives,
will be needed.
Removal
1
Disconnect the battery negative terminal
13.25a Disconnect the fuel return hose ...
13.24 Unscrew the union nuts securing the
high-pressure fuel pipe to the fuel pump
and fuel rail
(refer to Disconnecting the battery in the
Reference Chapter).
2 Remove the windscreen cowl panel as
described in Chapter 11.
3 Remove the plastic cover over the top of
the engine.
4 Release the locking catches securing the
wiring connectors to the four injectors, then
disconnect the injector wiring.
5 Undo the two bolts at the top and the two
bolts at the front, securing the plastic wiring
trough to the intake manifold (see illus-
trations 13.5a and 13.5b). Move the wiring
trough and injector wiring harness to one
side.
6
Thoroughly clean the fuel pipe unions on
the fuel rail and injector. Using two spanners,
hold the unions and unscrew the union nut
securing the high-pressure fuel pipe to the
fuel injector. Unscrew the union nut securing
the high-pressure fuel pipe to the fuel rail,
withdraw the pipe and plug or cover the open
unions to prevent dirt entry.
7 Disconnect the fuel leak-off hose connection
at each injector by pushing in the locking clip
and lifting out the hose fitting. Suitably plug or
cap the leak-off hose union on each injector,
and slip a plastic bag over the disconnected
leak-off hose to prevent dirt entry.
8 Unscrew the retaining nut then remove the
washer from the injector clamp bracket.
9 Withdraw the injector together with the
clamp bracket from the cylinder head. If
difficulty is experienced removing the injector,
liberally apply penetrating oil to the base of the
injector and allow time for the oil to penetrate.
13.25b ... then undo the two bolts
(arrowed) and remove the fuel rail