Plug Or Cap The Leak-Off Hose Union On Each Injector; Counter-Hold Injector Union When Unscrewing Fuel Pipe Unions; Unscrew Injector Clamp Bracket Retaining Nut Then Remove Washer; Using Small Slide Hammer To Free Injector Body From Cylinder Head - Opel Zafira B MPV 2006 Owners Workshop Manual

14.32b ... then plug or cap the leak-off
hose union on each injector
to the fuel rail, withdraw the pipe and plug or
cover the open unions to prevent dirt entry.
34 Starting with injector No 1, unscrew the
retaining nut then remove the washer from the
injector clamp bracket (see illustration).
35 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. 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 it free
(see illustration). 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.
36 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.
37 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).
38 Examine the injector visually for any signs
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
14.44a Fit the washer ...
Fuel and exhaust systems- diesel engines 48•11
14.33 Counter-hold the injector union
when unscrewing the high-pressure fuel
pipe unions
14.35 Using a small slide hammer to free
the injector body from the cylinder head
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.
39 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.
40 Prior to refitting, obtain a new set of copper
washers, retaining nuts and high-pressure fuel
pipes.
Refitting
41 Thoroughly clean the injector seat in the
cylinder head, ensuring all traces of carbon
and other deposits are removed.
42 Starting with injector No 4, locate a new
copper washer on the base of the injector.
43 Place the injector clamp bracket in the
slot on the injector body and refit the injector
to the cylinder head.
14.44b ... and the injector clamp bracket
retaining nut
14.34 Unscrew the injector clamp bracket
retaining nut then remove the washer
14.36 Once the injector has been removed,
separate it from the clamp bracket
44 Fit the washer and the injector clamp
bracket retaining nut and tighten the nut to the
specified torque (see illustrations).
45 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.
46 Tighten the fuel pipe union nuts to the speci-
fied torque using a torque wrench and crow-foot
adapter (see illustration). Counter-hold the
union on the injector with an open-ended
spanner, while tightening the union nut.
47 Repeat this procedure for the remaining
injectors.
48 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.
14.46 Tighten the fuel pipe union nuts to
the specified torque using a torque wrench
and crow-foot adapter