Remove The Copper Washer From The Injector Base; Undo Two Bolts And Remove Breather Pipe From Cylinder Head; Disconnect The Injector Wiring Connectors; Disconnect The Fuel Leak-Off Hose Connection At Each Injector - Opel Zafira B MPV 2006 Owners Workshop Manual

48•10 Fuel and exhaust systems - diesel engines
14.10 Remove the copper washer from the
injector base
If the injector is still reluctant to free, it will
be necessary to use a small slide hammer
engaged under the flange of the injector body
casting, and gently tap free. If available, use
Vauxhall/Opel special tools EN-46786 and
KM-328-B for this purpose. Note that it is not
possible to twist the injector from side-to-side
to free them due to the design of the clamp
bracket.
10 Once the injector has been removed,
separate it from the clamp bracket and remove
the copper washer from the injector base (see
illustration). The copper washer may have
remained in place at the base of the injector
orifice in the cylinder head. If so, hook it out
with a length of wire.
11 Remove the remaining injectors in the
same way. Label the injectors (1 to 4) so
they can be refitted in their original cylinders
(unless new injectors are to be fitted).
12 Examine the injector visually for any signs
14.30 Undo the two bolts (arrowed) and
remove the breather pipe from the cylinder
head
14.31b ... and disconnect the injector
wiring connectors
of obvious damage or deterioration. If any
defects are apparent, renew the injector.
Caution: The injectors are manufactured to
extremely close tolerances and must not be
dismantled in any way. Do not unscrew the
fuel pipe union on
the
side of the injector,
or
separate
any parts of
the
injector body.
Do not attempt to clean carbon deposits
from
the
injector nozzle or carry out any
form of ultrasonic or pressure testing.
13 If the injectors are in a satisfactory
condition, plug the fuel pipe union (if not
already done) and suitably cover the electrical
element and the injector nozzle.
14 Prior to refitting, obtain a new copper
washer a new retaining nut and new high-
pressure fuel pipe for each injector.
Refitting
15 Thoroughly clean the injector seat in the
cylinder head, ensuring all traces of carbon
and other deposits are removed.
16 Locate a new copper washer on the base
of the injector.
17 Place the injector clamp bracket in the
slot on the injector body and refit the injector
to the cylinder head.
18 Fit the washer and the new injector clamp
bracket retaining nut and tighten the nut to the
specified torque.
19 Remove the blanking plug from the fuel
pipe union on the fuel rail and the injector.
Locate the new high-pressure fuel pipe over
the unions and screw on the union nuts. Take
care not to cross-thread the nuts or strain the
fuel pipe as it is fitted.
20 Tighten the fuel pipe union nuts to the
14.31a Release the locking catches ...
14.32a Disconnect the fuel leak-off hose
connection at each injector ...
specified torque using a torque wrench and
crow-foot adapter (see illustration 14.46).
Counter-hold the union on the injector with
an open-ended spanner, while tightening the
union nut.
21 Repeat this procedure for the remaining
injectors.
22 Refit the wiring trough, and secure with
the four retaining bolts. Reconnect the wiring
connectors to the fuel injectors.
23 Reconnect the leak-off hose fittings to
the injectors by pushing in the locking clip,
attaching the fitting, then releasing the locking
clip. Ensure that each fitting is securely
connected and retained by the clip.
24 Reconnect the battery negative terminal.
25 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).
26 Refit the windscreen cowl panel as
described in Chapter 11 .
27 Refit the engine cover on completion.
DOHC (Z19DTHJ 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 Vauxha/1/0pel puller (KM-328-B) and
adapter (EN-46786) or suitable alternatives,
will be needed.
Removal
28
Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
29
Remove the plastic cover over the top of
the engine.
30 Release the retaining clip securing the
engine breather hose to the breather pipe
adjacent to the engine oil dipstick. Undo the
two bolts securing the breather pipe to the
cylinder head, and disconnect the pipe from
the hose (see illustration).
31 Release the locking catches securing
the wiring connectors to the four injectors,
then disconnect the injector wiring (see
illustrations).
32 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 (see illustrations).
33 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 (see illustration). Unscrew the
union nut securing the high-pressure fuel pipe