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Chapter 4 Part C:
Fuel and exhaust systems - diesel engine
Contents
Accelerator pedal and position sensor - removal and refitting . . . . . 3
Air cleaner assembly and intake ducts - removal and refitting . . . . . 2
Air cleaner filter element renewal . . . . . . . . . . . . . . . . .See Chapter 1B
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . 15
Exhaust system -general information, removal and refitting . . . . . . 16
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1B
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . ..See Chapter 1B
Fuel filter water draining . . . . . . . . . . . . . . . . .: . . . . . .See Chapter 1B
Fuel gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . . 5
Fuel injection pump - removal and refitting . . . . . . . . . . . . . . . . . . . . 9

Fuel injectors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel system - priming and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Injection system electrical components - removal and refitting . . . . 8
Injection timing - checking and adjustment . . . . . . . . . . . . . . . . . . .10
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .14
Intercooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maximum speed -checking and adjustment . . . . . . . . . . . . . . . . . . 7
Turbocharger - removal and refitting . . . . . . . . . . . . . . . . . . . . . . ..12

Degrees of difficulty
' , Dicutt, suitable for

Easy, surtable for
novice w
ith little
expenence

suitable for competent ~

P

--

DIY
l experienced
i
mehanic

PP

l

P

Verydicutt,
suitable for expert DIY \
or professional

a

Specifications
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECD V5 direct injection system incorporating an electronicallycontrolled Nippon Denso V5 distributor fuel injection pump with
integral transfer pump. Two stage injectors with pilot and post
injection. Turbocharger fitted to all models and intercooler on Yl7DT
engined models

Adjustment data
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 to 875 rpm - controlled by ECU
Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5060 to 5180 rpm - controlled by ECU

injection pump
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump timing (static):
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer fuel pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise, viewed from sprocket end
0.28 to 0.33 mm pump plunger travel Q TDC
0.33 mm pump plunger travel Q TDC
8.0 i 0.1 bars at 2200 rpm

injectors
Opening pressure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 bar (1st stage) to 335 bar (2nd stage)

Torque wrench settings
Accelerator pedal/position sensor . . . .
Air conditioning compressor bracket . .
Air conditioning compressor . . . . . . . . .
Charge pressure sensor . . . . . . . . . . . .
Coolant temperature sensor . . . . . . . . .
Crankshaft sensor . . . . . . . . . . . . . . . . .
Electronic control unit . . . . . . . . . . . . . .

Ibf ft
7
32
16
7
16
7
4

4C

4 0 2 Fuel and exhaust systems - diesel engine
Torque wrench settings (contnued)
Exhaust front pipe-to-turbocharger nuts . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold:
Retaining nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...............................
Fuel injector return pipe u r,ions
'
Fuelinjectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuelpipeunionnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueltank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection pump:
Central bleed screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump to pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pumptotimingcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing belt sprocket nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
inlet manifold nuts and bolts* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oilpressureswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil return line banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger:
Exhaustflangenuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil feed line adaptor to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil feed line to turbocharger/block adaptor . . . . . . . . . . . . . . . . . . . .
Turbocharger-to-manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Use new fasteners

l

I

1 General information
and precautions

General information
1 The fuel supply system consists of a fuel
tank (which is mounted under the rear of the
car), a fuel filter with integral water separator
(in the engine compartment), an electronicallycontrolled distributor fuel injection pump with
integral transfer pump, injectors and
associated components.
2 Fuel is drawn from the fuel tank by the fuel
injection pump. Before reaching the pump,
the fuel passes through a fuel filter, where
foreign matter and water are removed. Excess
fuel lubricates the moving components of the
pump, and is then returned to the tank.
3 The fuel injection pump is driven at halfcrankshaft speed by the timing belt. The high
pressure required to inject the fuel into the
compressed air in the cylinder is achieved by
radial plungers.
4 The injection pump is electronicallycontrolled to meet the latest emission
standards. The system consists of the engine
electronic control unit, the injection electronic
control unit, and the following sensors:
a) Accelerator pedal position sensor - informs
the ECUs of the accelerator pedal position.
b) Coolanf temperature sensor - informs the
ECUs of engine temperature.
c) lntake air temperature sensor - informs
the ECUs of the temperature of the air
passing through the intake ducf.
d) Hot film mass airflow meter - informs the
ECUs of ?,he amount of airpassing
through the intake duct.

e) Crankshaft sensor - informs the ECUs of
engine speed and crankshaft position.
f) Charge pressure sensor - informs ECUs
of the pressure in the inlet manifold.
g) ABS control unit - informs the ECUs of
the vehicle speed.
h) Atmospheric pressure sensor - informs
the ECUs of the atmospheric pressure.
i) Fuel temperature sensor - informs the
ECUs of the fuel temperature.
j) injection pump shaft sensor - used by the
ECUs to determine the exact injection
timing.
k) Oil pressure switch - used by the engine
ECU to control the instrument cluster oil
warning lamp.
I) Clutch switch - used by the ECUs for
cruise control functions.
m)Air conditioning system compressor
switch (where fitted) -informs the ECUs
when the air conditioning system is
switched on.

Ibf ft
49

8 The four fuel injectors produce a spray of
fuel directly into the cylinders. The injectors
are calibrated to open and close at critical
pressures to provide efficient and even
combustion. Each injector needle is lubricated
by fuel which accumulates in the spring
chamber and is channelled to the injection
pump return hose by leak-off pipes.
9 The inlet manifold is a two-part assembly
sealed by a metal gasket. The EGR (exhaust
gas recirculation) valve and charge pressure
sensor are mounted to the upper part of the
manifold.
10 A turbocharger is fitted to increase engine
efficiency by raising the pressure in the inlet
manifold above atmospheric pressure.
Instead of the air simply being sucked into the
cylinders, it is forced in. Additional fuel is
supplied by the injection pump in proportion
to the increased air intake.
11 Energy for the operation of the
turbocharger comes from the exhaust gas.
The gas flows through a specially-shaped
housing (the turbine housing) and in so doing,
5 All the above information is analysed by the
ECUs and, based on this, the ECUs determine spins the turbine wheel. The turbine wheel is
the appropriate injection reqliirements for the attached to a shaft, at the end of which is
engine. The engine ECU controls the injection another vaned wheel known as the
pump timing, via the pump control unit, to compressor wheel. The compressor wheei
provide the best setting for cranking, starting spins in its own housing, and compresses the
(with either a hot or cold engine), warm-up, inlet air on the way to the inlet manifold.
12 Between the turbocharger and the inlet
idle, cruising, and acceleration.
6 Basic injection timing is determined when manifold, the compressed air passes through
the pump is fitted. When the engine is an intercooler (except Y20DTL engine). This is
running, it is varied automatically to suit the an air-to-air heat exchanger mounted next to
prevailing engine speed by a mechanism the radiator, and supplied with cooling air
which turns the cam plate or ring - controlled from the front of the vehicle. The purpose of
the intercooler is to remove some of the heat
by the ECU.
7 The engine ECU also controls the exhaust gained in being compressed from the inlet air.
gas recirculation (EGR) system (see Chapter 4D) Because cooler air is denser, removal of this
heat further increases engine efficiency.
and the pre-heating system (see Chapter 5C).

Fuel and exhaust systems - diesel engine 4 0 3
Caution: Do not operate the engine if any
of air intake ducts are disconnected or the
filter element is removed. Any debris
entering the engine will cause severe
damage to the turbocharger.
Caution: To prevent damage to the
turbocharger, do not race the engine
immediately after start-up, especially if it is
cold. Alfow it to idle smoothly to give the oil
a few seconds to circulate around the
turbocharger bearings. Always allow the
engine to return to idle speed before
switching it off do not blip the throttle
and switch off, as this will leave the turbo
spinning without lubrication.
Caution: Observe the recommended
intervals for oil and filter changing, and use
oil of the specified quality. Neglect of oil
changing, or use of inferior oil, can cause
carbon formation on the turbo shaft,
leading to subsequent failure.

-

2.la Air cleaner and ducting
Air cleaner housing
Hot film mass airflow
meter

- 17DTL engine

3 Air intake hose
4 Air intake manifold
5 Charge air pipe

13 Charge pressure (the pressure in the inlet
manifold) is limited by a wastegate, which
diverts the exhaust gas away from the turbine
wheel in response to a pressure-sensitive
actuator. A pressure-operated switch
operates a warning light on the instrument
panel in the event of excessive charge
pressure developing.
14 The turbo shaft is pressure-lubricated by
an oil feed pipe from the engine main oil so
that the shaft 'floafs' on a cushion of oil. A
drain pipe returns the oil to the sump.
15 The charge pressure wastegate is
controlled by the ECU via a solenoid valve.
16 If there is an abnormality in any of the
readings obtained from any sensor, the ECU
enters its back-up mode. In this event, the
ECU ignores the abnormal sensor signal, and
assumes a preprogrammed value which will
allow the engine to continue running (albeit at
reduced efficiency). If the ECU enters this
back-up mode, the warning light on the
instrument panel will come on, and the
relevant fault code will be stored in the ECU
memory.
17 If the warning light comes on, the vehicle
should be taken to a Vauxhall dealer at the
earliest opportunity. A complete test of the
injection system can then be carried out,
using a special electronic diagnostic test unit
which is simply plugged into the system's
diagnostic connector. The connector is
located behind the centre of the facia.

Precautions
Warning: I t is necessary to take
certain precautions when working
on the fuel system components,
particula'arly the fuel injectors. Before

6 Charge air hose
7 Resonatorlair intake pipe
8 Connectinghose

carrying out any operations on the fuel
system, refer to the precautions given in
'Safety first!' at the beginning of this
manual, and to any additional warning
notes at the start of the relevant Sections,

Mote: The intercooler is only fitted to the
Y17DT engine.
1 Disconnect the wiring from the hot film
mass airflow meter by releasing it towards the
air cleaner cover (see illustrations).

2.1 b Air cleaner and ducting

7 Air cleaner housing
2 Hot film mass airflow
meter
3 Air intake hose
4 Air intake manifold

5
6
7
8
9

- 17DT engine

Upper charge air pipe
Charge air hose
Charge air hose
Intercooler
Charge air hose

10 Lower charge air pipe
7 1 Centre charge air pipe
12 Resonatorlair intake
pipe
13 Connecting hose

4 0 4 Fuel and exhaust systems - diesel engine

2.2a Loosen the clip.

2.3a Undo the screws..

2.2b

.

...

and disconnect the mass airflow
meter from the air cleaner cover

2 . 2 ~Disconnectingthe air duct from the
pipe at the rear of the engine

...and lift the cover from the air

2.4 Removing the element

2.3b

cleaner

2 Loosen the clip and disconnect the hot film
mass airflow meter from the air cleaner cover.
disconnect the duct from the
intermediate pipe at the rear of the engine
(see illustrations).
3 Undo the screws and lift the cover from the
air cleaner (see illustrations).
4 Lift out the element (see illustration).
5 D~sconnectthe air inlet duct from the front
of the air cleaner (see illustration).
6 Unscrew the crossbar mounting bolt from
the rear of the air cleaner, and release the
crossbar from the rear rubber mountings (see
illustration).
7 Pull the air cleaner body rearwards from the
front mounting rubber, and withdraw from the
engine compartment (see illustration).
8 The remaining ducts linking the
turbocharger, intercooler and inlet manifold
can be removed once their retaining clips and
(where necessary) bolts have been slackened.

2.5 Removing the air inlet duct from the
front of the air cleaner

Refitting
-

Refitting

g Refitting is the reverse of removal, ensuring
that all intake ducts are properly reconnected
and their retaining clips securely tightened.

4 Refitting is a reversal of removal. After
reconnecting the battery, havs a Vauxhall
dealer reprogram the volatile memories.

3 Accelerator pedal
and position sensor
removal and refitting

-

Removal
1 Disconnect the battery negative lead (refer
to Disconnectingthe battery at the end of this
manual).
2 Working in the driver's footwell under the
facia, disconnect the wiring from the top of
the accelerator pedallposition sensor. Where
necessary, pull back the footwell carpet first.
3 Unscrew the three mounting nuts, and
withdraw the sensor from the bulkhead.

2.6 Removing the mounting crossbar from
the rear of the air cleaner

1 It is not necessary to manually prime and
bleed the fuel system after any operation on
the system components. Start the engine,
noting that this may take longer than usual,
especially if the fuel system has been allowed
to run dry. Operate the starter in ten second
bursts with 5 seconds rest in between each
operation, for a maximum of 40 seconds.
When the engine starts, run it at a fast idle
speed fo[ a minute or so to purge any trapped

2.7 Removing the air cleaner assembly

Fuel and exhaust systems - diesel engine 4 0 5

5.4 Prise the plastic cover from the floor
for access to the fuel gauge sender cover

5.5 Using the special tool to release the
fuel line connectors

5.6 Disconnecting the main wiring plug

5.7 Tapping the locking ring anticlockwise to release it

5.8 Removing the locking ring

5.9 Disconnect the fuel gauge sender
wiring plug

air from the fuel lines. After this time the engine
should idle smoothly at a constant speed.
2 If the engine idles roughly, then there is still
some air trapped in the fuel system. Increase
the engine speed again for another minute or
so then recheck the idle speed. Repeat this
procedure as necessary until the engine is
idling smoothly.

Note: Refer to the precautions given in
Section 1 before proceeding.
Note: The fuel tank should be as empty as
possible when carrying out this procedure.

Removal

,

1 Disconnect the battery negative lead (refer

5.10 Disconnecting the fuel supply hose
from the cover

to Disconnectingthe battery at the end of this similar tool, to depress the retaining tangs.
Clamp or plug the open ends of the hoses, to
manual).
2 Syphon out any remaining fuel in the tank prevent dirt ingress and further fuel spillage.
through the filler pipe into a clean metal 6 Disconnect the main wiring plug from the
cover (see illustration).
container which can be sealed.
3 On Hatchback models, remove the rear 7 Release the fuel gauge sender cover
seat as described in Chapter 11. On standard locking ring. A special tool (Vauxhall tool No
Van models, fold up the rear seat. On Combo KM-797) is available for this, but the ring can
Van models, unbolt the tank cover flap from be removed by tapping anti-clockwise until
the locking clips release (see illustration).
the rear floor.
4 Fold up the acoustic insulation, then, using 8 Remove the locking ring, then carefully lift
a screwdriver, carefully lever out the plastic off the cover, noting the location of the wiring
cover to expose the fuel gauge sender cover and hose connections (see illustration).
9 Disconnect the sender unit wiring from the
(see illustration).
5 Identify the position of the fuel feed and bottom of the cover (see illustration).
return lines, then disconnect the quick-release 10 Release the clip and disconnect the fuel
fittings. Be prepared for some loss of fuel. A supply hose from the cover (see illustration).
Vauxhall special tool is available to release the 11 Disconnect the fuel return hose, and
fuel line connectors (see illustration), but withdraw the cover.
provided care is taken, the connectors can be 12 Remove the cover sealing ring (see
released using a pair of long-nosed pliers, or a - illustration).

5.12 Removing the cover sealing ring

5.13a Depress the hook

.. .

4 0 6 Fuel and exhaust systems - diesel engine

5.13b

. ..pull the sender unit from the
housing

13 Depress the hook and pull the sender unit
from the clips on the side of the housing (see
illustrations).

Refiffing
14 Refitting is a reversal of removal, bearing
in mind the following points:
a) Check the condition of the sealing ring on
the underside of the fuel pump cover, and
renew if necessary.
b) Refit the fuel pump cover locking ring by
tapping it clockwise until the locking clips
'click' into position.

Note: Refer to the precautions given in
Section 1 before proceeding.
Note: The fuel tank should be as empty as
possible when carrying out this procedure.

Removal
1 Disconnect the battery negative lead (refer
to Disconnecting the battery at the end of this
manual).
2 Syphon out any remaining fuel in the tank
through the filler pipe into a clean metal
container which can be sealed.
3 Chock the front wheels then jack up the
rear of the vehicle and support on axle stands
(see Jacking and vehicle support). Remove
both rear wheels.

8.1 Slide the lock to disconnect the wiring
from the mass airflow meter

4 Refer to Chapter 9 and disconnect the front
ends of the rear (secondary) handbrake
cables from the u~derbodyclips after backing
off the primary cable adjustment. Unclip the
cables from the underbody and the right-hand
side of the fuel tank, then tie them to one side,
away from the fuel tank.
5 Disconnect the rear of the exhaust system
from its rubber mountings, and lower the
system, then move it to one side sufficiently to
enable removal of the fuel tank. Alternatively,
remove the exhaust system completely to
provide greater clearance (refer to Section 16).
6 Disconnect the wiring from the fuel gauge
sensor, at the connector on the underbody.
7 Disconnect the fuel feed and return lines at
the quick-release connectors on the
underbody (if necessary, detach the line
retaining bracket from the underbody). Be
prepared for some loss of fuel. A Vauxhall
special tool is available to release the fuel line
connectors, but provided care is taken, the
connectors can be released using a pair of
long-nosed pliers, or a similar tool, to depress
the retaining tangs.
8 Unscrew the lower filler hose mounting bolt,
then unclip the ventilation hose from the
bottom of the fuel tank.
9 Loosen the clip and disconnect the fuel
filler hose from the fuel tank.
10 Support the weight of the fuel tank on a
jack with interposed block of wood.
11 Unbolt and remove the two securing
straps from the fuel tank.
12 Lower the tank sufficiently to enable
access to the fuel hoses on the tank, then
disconnect them. Be prepared for some loss
of fuel.
13 Continue to lower the tank until it can be
removed from under the vehicle.
14 Plug or clamp the fuel and vent hoses to
prevent entry of dust and dirt.
15 If necessary, remove the fuel lines and
hoses, heat shield and wiring from the tank for
transfer to the new tank. If a new tank is being
fitted, it is recommended that the filter is
renewed at the same time.

Refiffing
16 If the tank contains sediment or water, it
may cleaned out with two or three rinses of
clean fuel. Remove the fuel gauge sender unit
as described in Section 5 . Shake the tank
vigorously, and change the fuel as necessary
to remove all contamination from the tank.
This procedure should be carried out in a wellventilated area, and i t is vital to take adequate
fire precautions.
17 Any repairs to the fuel tank should be
carried out by a professional. Do not under
any circumstances attempt any form of DIY
repair to a fuel tank.
18 Refitting is a reversal of removal, bearing
in mind the following points:
a) Ensure that all hoses are securely
reconnectedto their correct locations.
b) Check the handbrake cable adjustment,
as described in Chapter 9.

c) On completion, fill the fuel tank, then run
the engine and check for leaks. I f leakage
is evident, stop the engine immediately
and rectify the problem without delay,

Caution: The maximum speed is contm!led
by the ECU and cannot be adjusted by the
home mechanic. The speed can be
checked using a tachometer as described
below, but if adjustment is needed it will be
necessary to take the vehicle to a Vauxhall
dealer. They will have access to the
necessary diagnostic equipment required
to test and adjust the settings.
1 Run the engine to normal operating
temperature.
2 Have an assistant fully depress the
accelerator pedal, and check that the
maximum engine speed is as given in the
Specifications. Do not keep the engine at
maximum speed for more than two or three
seconds.

Hot film mass airflow meter
Note: The intake air temperature sensor is
built into the airflow meter. ,

Removal
1 Ensure the ignition is switched off and
disconnect the wiring plug from the hot film
mass airflow meter. To do this, slide the lock
towards the air cleaner (see illustration).
2 Release the retaining clips then free the
airflow meter from the air cleaner cover and
intake duct. Remove it from the engine
compartment.

Refitting
3 Refitting is the reverse of removal, ensuring
the airflow meter is correctly seated in the air
cleaner and duct and the retaining clips are
securely tightened.

Crankshaft sensor
Removal
4 Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands
(see Jacking and vehicle support). Remove
the engine undertray.
5 The sensor Ts located on the rear of the
cylinder block, beneath the starter motor.
Working from under the vehicle, disconnect
the wiring plug from the sensor.
6 Undo the retaining bolt and remove the
sensor. Recover the sealing ring (see
illustration).

Fuel and exhaust systems - diesel engine 4 0 7

8.6 Crankshaft position sensor

Refitting
7 Refitting is a reversal of removal. If necessary
renew the sealing ring and tighten the sensor
retaining bolt to the specified torque.

Coolant temperature sensor
Removal
8 With reference to Chapter 3, drain the
coolant system, or be prepared for coolant
spillage.
9 The coolant temperature sensor is located
in the thermostat housing at the left-hand end
of the cylinder head. Disconnect the wiring
plug from the sensor (see illustration).
10 Unscrew the sensor from the thermostat
housing. Mop up any spilled coolant.

Refitting
11 Apply a little locking compound to the
threads of the sensor, and refit the sensor to
the housing. Tighten the sensor to the
specified torque.
12 Reconnect the wiring plug to the sensor.
13 Top-up the coolant system (see Weekly
checks or Chapter 3).

8.9 Engine coolant temperature sensor
21 The oil pressure switch is located at the
left-hand, rear end of the cylinder block. For
improved access, remove the battery and
battery tray as described in Chapter 5A.
22 Unclip the coolant expansion tank hose
and position to one side.
23 Disconnect the wiring plug from the
switch.
24 Unscrew the switch from the cylinder
block. Be prepared for some oil spillage (see
illustration).

Refitting
25 Apply some suitable silicone sealant
(available from Vauxhall dealers) to the
threads, and screw the switch into place.
Tighten the switch to the specified torque.
26 Reconnect the wiring plug, locate the
expansion tank hose in the clip, and refit the
battery tray and battery where removed.
27 Start the vehicle and check for oil leaks.

8.18 Undo the bolts and remove the
charge pressure sensor

Engine electronic control unit
(=U)
Removal
28 The engine control unit is located on top
of the engine above the exhaust gas
recirculation valve.
29 Disconnect the battery negative lead
(refer to Disconnecting the battery in the
Reference Chapter).
30 Disconnect the wiring plugs from the ECU.
The two main plugs are unlocked by lifting up
the metal levers, and this is best achieved
using two screwdrivers (see illustrations).
31 Unbolt and remove the wiring harness
bracket from the top of the ECU.
32 Unscrew the mounting bolts and nuts, and
remove the ECU from the mounting bracket.
33 Release the glow plug wiring, then
unscrew the two mounting bolts and single
nut, and remove the ECU mounting bracket.

Charge pressure sensor
Removal
14 The charge pressure sensor is located on
the right-hand rear end of the inlet manifold.
15 Loosen the clips and remove the air intake
hose from above the inlet manifold.
16 Remove the exhaust gas recirculation
(EGR) solenoid valve from the inlet manifold
as described in Part D of this Chapter.
17 Disconnect the wiring plug from the
sensor.
18 Unscrew the mounting bolt and remove
the sensor (see illustration).

8.24 Oil pressure switch

8.30a Using two screwdrivers to lift the
metal lock levers.

..

Refitting
19, Refitting is a reversal of removal. Tighten
the sensor retaining bolt to the specified
torque.

Oil pressure switch
Removal
20 The signal from the oil pressure switch is
used by the injection control unit to determine
whether or not to illuminate the oil pressure
warning light.

8.30b

. ..in order to disconnect the main
plugs from the engine ECU

8 . 3 0 ~Disconnectingthe central wiring

4C.8

Fuel and exhaust systems - diesel engine
37 Apply the handbrake, then jack up the
front of the vehlcle and support ~t on axle
stands (see Jacking and vehicle support)
Remove the englne undertray
38 Worklng under the vehlcle, disconnect the
ECU wlrlng plug (see ~llustration)
39 Undo the retalnlng bolts, and remove the
ECU (see illustrat~on)

Refitting

8.38 Wiring plug on the injection
electronic control unit

40 Reflttlng IS a reversal of removal, but
tlghten the bolts to the speclfled torque
F~nally,~tmay be necessary to have a Vauxhall
dealer program all volatile memories.

8.39 Unscrew the injection ECU retaining
bolts

Fuel temperature sensor
Removal
41 The fuel temperature sensor is fitted to the
right-hand top of the injection pump (see
illustration).
42 To remove the sensor, disconnect the
wiring plug and unscrew the sensor from the
top of the injection pump.

Refitting
43 With a new seal fitted, screw the sensor
into the injection pump and tighten the nut
securely (see illustration).
44 Reconnect the wiring plug.

Injection pump shaft position
sensor
45 The sensor is located on the side of the
fuel injection pump.
46 The sensor may not be available as a
separate item. Check with a Vauxhall dealer
prior to any attempt to remove the sensor.

Injection commencement sensor

I

I
8.41 Fuel injection pump

1 Spill valve
2 Fuel return line
3 Fuel temperature sensor

4 Fuel supply line
5 Programmable read-only
memory

Refitting
34 Refitting is a reversal of removal. Tighten
the ECU retaining bolts/nuts to the specified

6 Timing control solenoid
7 Injection pump shaft
position sensor

torque. The ECU wiring plugs are shaped
such that each plug will only fit its correct
socket. The plug from the left-hand side of the
e n ~ i n e compartment connects to the
rearmost sodket. Take great care when
refitting the plugs, as the terminals are very
delicate and easily damaged. Finally, it may
be necessary to have a Vauxhall dealer
program all volatile memories.

Injection electronic control unit
(=U)
Removal

8.43 Screw the fuel temperature sensor
into the injection pump

35 The injection ECU is located on the rear of
the engine, beneath the injection pump.
Access is best from beneath the vehicle.
36 Disconnect the battery negative lead
(refer to Disconnecting the battery in the
Reference Chapter).

47 The sensor is located on the underside of
the fuel injection pump at the flywheel end.
48 The sensor may not be available as a
separate item. Check with a Vauxhall dealer
prior to any attempt to remove the sensor.

Fuel cut-off solenoid
49 The fuel cut-off solenoid is located on top
of the fuel injection pump, at the flywheel end.
50 The solenoid may not be available as a
separate item. Check with a Vauxhall dealer
prior to any attempt to remove the sensor.

9 Fuel injection pump
removal and refitting

-

Caution: Be careful n o t to allow dirt into
the injection pump or injector pipes during
this procedure.

Removal
1 Disconnect the battery negative lead (refer
to Disconnecting the battery in the Reference
Chapter).
2 Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands
(see Jacking and vehicle support). Remove
the right-hand front roadwheel and the inner

Fuel and exhaust systems - diesel engine 4 0 9
wheel arch liner for access to the crankshaft
pulley. Remove the engine compartment
undertray.
3 Remove the timing belt and injection pump
sprocket as described in Chapter 2C.
4 Disconnect the wiring plugs from the
engine electronic control unit (ECU) located
on the top of the engine. The two main plugs
are unlocked by lifting up the metal levers.
5 Disconnect the crankcase ventilation hose
from the camshaft cover then unscrew the
mounting bolts and disconnect the air intake
pipe from the turbocharger. Also disconnect the
clips and remove the centre charge air hose.
6 Remove the engine electronic control unit
(ECU) and mounting bracket as described in
Section 8.
7 Unscrew the nuts and remove the starter1
alternator wiring harness bracket from the
EGR valve.
8 Unscrew the studs and bolts and remove
the centre charge air metal pipe.
9 Disconnect the wiring from the glow plugs.
10 Remove the EGR valve and EGR solenoid
valve as described in Part D of this Chapter.
11 Unbolt and remove the right-hand engine
lifting eye.
12 Remove the charge pressure sensor as
described in Section 8.
13 Place a suitable container beneath the oil
filter housing, then unscrew the cover and
remove the filter element.
14 Release the clip and disconnect the oil
return line from the oil filter housing.
15 Remove the protective insulator (where
fitted), then unscrew the bolts and remove the
three clamps from the injector lines (see
illustrations). Also, unscrew the union nuts
and remove the lines from the injection pump
and injectors.
16 Unscrew the union bolt and the mounting
bolt securing the oil return line to the cylinder
head, then release the clip and disconnect the
oil return hose.
17 Disconnect the three wiring plugs from
the injection pump (see illustration).
18 Progressively unscrew the mounting bolts
and nuts, and remove the inlet manifolds from
the cylinder head. Recover the gaskets.
19 Disconnect the fuel supply and return
hoses from the injection pump.
20 Note its location, then carefully unscrew
the fuel return check valve from the injection
pump (see illustration). Do not unscrew the
check valve from the banjo bolt. Tape over or
plug the fuel return aperture to prevent entry
of dust and dirt.
21 Unscrew the bolt and reriove the injection
pump outer insulation, then disconnect and
unclip the engine management wiring, and
carefully lever off the inner insulation. Note the
routing of the various wiring looms.
22 Unbolt the mounting bracket from the lefthand end of the pump (see illustration).
23 Disconnect the PROM (Programmable
Read-Only Memory) wiring harness plug, then
unscrew the two retaining nuts, and
manoeuvre the injection pump from the timing

9.15a Fuel injection pump protective
insulator

9.15b Injector line clamp

9.17 Injection pump wiring plugs

9.20 Fuel return check valve

case. Recover the foam insulator from
between the pump and cylinder block.
Caution: Never attempt to dismantle the
pump assembly. If there is a problem, take
the pump to a Vauxhall dealerldiesel
injection specialist for testinglrepair.

the wiring plug to the PROM on the side of the
pump before fitting the rearmost foam
insulation piece.
26 Reconnect the wiring and insulation, and
tighten the bolt.
27 Refit the fuel return check valve and
tighten the banjo bolt securely.
28 Reconnect the fuel supply and return
hoses.
29 Refit the inlet manifolds together with new
gaskets, and tighten the nuts and bolts to the
specified torque.
30 Reconnect the pump wiring, then refit the
oil return line and hose.
31 Reconnect the oil return line to the oil filter
housing.
32 Insert a new oil filter element, then refit the
cover and tighten.
33 Refit the charge pressure sensor with
reference to Section 8.
34 Refit the engine lifting eye.

Refitting
24 To refit the pump, hold the correct piece
of foam insulator against the cylinder block,
engage the pump shaft with the
corresponding hole in the timing case, and fit
the two retaining nuts. Hand-tighten the nuts
at this stage.
25 Refit the pump mounting bracket to the
cylinder block, and tighten the bolts to the
specified torque. Fit the bolts securing the
bracket to the pump, then fully tighten the
pump mounting nuts and bolts to the specified
torque. Refit the foam insulation pieces around
the pump (see illustration). Note: Reconnect

9.22 Fuel injection pump mounting
bracket and bolts

9.25 Refit the foam insulation pieces

4 0 1 0 Fuel and exhaust systems - diesel engine
Caution: Be careful not to allow dirt into
the injection pump or injector pipes during
this procedure.
Caution: Some of the injection pump
settings and access plugs may be sealed
by the manufacturers at the factory, using
paint or locking wire and lead seals. Do not
disturb the seals if the vehicle is still within
the warranty period, otherwise the
warranty will be invalidated. Also do not
attempt the timing procedure unless
accurate instrumentation is available.
1 Remove the air cleaner housing and
10.4 Remove the central bleed screw
ducting (Section 2)
2 Undo the unions and remove the fuel
35 Refer to Part D and refit the EGR solenoid - injection delivery pipes. We found it necessary
to remove the oil cooler housing retaining bolt
valve and EGR valve.
(see Chapter 2C) and push the housing to the
36 Reconnect the wiring to the glow plugs.
37 Refit the timing belt and injection pump rear, to allow sufficient access to the rear of
the pump. Be prepared for fluid spillage.
sprocket as described in Chapter 2C.
38 Carry out the injection timing checking 3 With reference to Chapter 2C, position the
and adjustment procedure described in crankshaft at approximately 45" before TDC
for No 1 piston.
Section 10.
4 Remove the central bleed screw from the
39 Refit the injector lines and clamps.
40 Refit the centre charge air metal pipe, and centre of the four fuel delivery unions at the
left-hand end of the injection pump (see
starterlalternator wiring harness bracket.
41 Refit the engine electronic control unit illustration).Recover the seal.
(ECU) and mounting bracket with reference to 5 Screw the adapter into the rear of the pump
and mount the dial gauge in the adapter (see
Section 8.
42 Reconnect the centre charge air hose, illustration). The special adapter and dial
turbocharger air intake pipe and crankcase gauge (Vauxhall tool No KM-798) can be
purchased from most good motor factors.
ventilation hose.
Position the dial gauge so that its plunger is at
43 Reconnect the wiring plugs to the ECU.
the
mid-point of its travel and securely tighten
44 Refit the wheel arch liner and roadwheel,
the adapter locknut.
and lower the vehicle to the ground.
45 Reconnect the battery negative lead (refer 6 Slowly rotate the crankshaft back-and-forth
to Disconnecting the battery in the Reference whilst observing the dial gauge, to determine
when the injection pump plunger is at the
Chapter).
46 Finally, it may be necessary to have a bottom of its travel (BDC). When the pump
Vauxhall dealer program all volatile memories. plunger is correctly positioned, zero the dial
gauge.
7 Rotate the crankshaft slowly in the correct
direction until the crankshaft pulley TDC mark
10 Injection timing
is correctly aligned with the pointer (No 1
checking and adjustment
cylinder at TDC on its compression stroke).
8 The reading obtained on the dial gauge
Note: Although on these models the injection should be equal to the specified pump timing
timing is determined by the engine ECU, the measurement given in the Specifications at
basic injection timing has to be set when the the start of this Chapter. If adjustment is
pump is fitted. Actual checking of the injection necessary, slacken the pump front mounting
system can only be carried out using specialist nuts and rear mounting bolts and slowly
rotate the pump body until the point is found
diagnostic esui~ment.
where the specified reading is obtained. Note:
I f necessary remove the upper timing belt
cover for access to the nuts and bolts. If the
reading is too large turn the pump towards the
engine, and if the reading is too small turn the
pump away from the engine. When the pump
is correctly positioned, tighten both its front
and rear mounting nuts and bolts to the
specified torque.
9 Rotate the crankshaft through one and
three quarter rotations in the normal direction
of rotation. Find the injection pump plunger
BDC as described in paragraph 6 and zero the
dial aauae.
10.5 Screw the adapter into the Pump and
10 Gotate the crankshaft slowly in the correct
mount the dial gauge
direction of rotation until the crankshaft pulley

-

S?

8

mark is realigned with the pointer (bringing the
No 1 cylinder piston back to TDC). Recheck
the timing measurement.
11 If adjustment is necessary, slacken the
pump mounting nuts and bolts and repeat the
operations in paragraphs 8 to 10.
12 When the pump timing is correctly set
unscrew the adapter and remove the dial
gauge.
13 Inspect the seal and renew if necessary,
then refit the central bleed screw and tighten
it to the specified torque.
14 Refit the fuel injection pipes, tightening the
unions to the specified torque, and refit the oil
cooler housing and retaining bolt (if removed).
15 Where removed, refit the upper timing belt
cover, then refit the air filter housing and
ducting.
16 The fuel system should 'self-bleed' as the
engine is cranked, although it may take longer
than normal to restart. Check for fuel leaks
from the disturbed pipes and unions.

-

11 Fuel injectors
removal and refitting

Q

P

II
Warning:
Exercise
extreme
caution when working on the fuel
injectors. Never expose the hands
or any part of the body to injector spray, as
the high working pressure can cause the
fuel to penetrate the skin, with possibly
fatal results. You are strongly advised to
have any work which involves testing the
injectors under pressure carried out by a
dealer or fuel injection specialist.
Caution: Be careful not to allow dirt into
the injection pump, injectors or pipes
during this procedure.
Caution: Take care not to drop the
injectors, or allow the needles at their tips
to become damaged. The injectors are
precision-made to fine limits, and must not
be handled roughly, In particular, never
mount them in a bench vice.

Removal
l Remove the camshaft cover as described in
Chapter 2C.
2 Drain the cooling system as described in
Chapter 1B. Note: This is recommended by
the manufacturers as a precaution against
coolant entering the combustion chambers
when the fuel injectors are removed, as a
result of the injector heat sleeves becoming
displaced.
3 Undo the five bolts and remove the inner
fuel leak-back pipe. Recover the copper
washers (see illustrations).
4 Slacken and remove the retaining nuts, and
remove the injector clamps (see illustration).
5 Lift the injectors out of the cylinder head.
Discard the rubber seals and copper washers;
new seals/washers must be fitted prior to
reassembly. Do not attempt to dismantle the
injectors any further.

Fuel and exhaust systems - diesel engine 4 0 1 1
6 Testing of the injectors requires the use of
special equipment. If any injector is thought to
be faulty have it tested and, if necessary,
reconditioned by a diesel engine specialist or
Vauxhall dealer.

Refitting
7 Commence reassembly by ensuring that
the injector and cylinder head mating faces
are clean, and fitting new copper sealing
washers and rubber seals to each injector.
Note the correct orientation of the copper
washers (see illustration).
8 Carefully fit each injector into the cylinder
head, and secure them in place by fitting the
injector clamps. Tighten the clamp retaining
nuts to the specified torque.
9 Refit the inner fuel leak-back pipe to the
injectors and the camshaft housing. The larger
diameter bolt secures the leak-back pipe to
the camshaft housing. Note that new copper
washers should be fitted to the top of each
injector, and the underside of each bolt.
Reconnect the pipe to the camshaft housing
using new copper washers. Tighten the bolts
to the specified torque.
10 Refit the camshaft cover as described in
Chapter 2C.
11 Refill the cooling system as described in
Chapter 1B.
12 Restart the engine and check for leaks.

fuel leak-back pipe unions on the
injectors..

.

11.3b

. . . and the union on the camshaft
housing

11.4 The injector clamp washer fits dished
with the side facing down

11.7 Note the rubber seal and copper
washer

oil return pipe union and gasket (see
illustration).
6 Slacken and remove the four mounting nuts
then remove the turbocharger and gasket
from the manifold (see illustration).

7 Unscrew the bolts securing the wastegate
unit to the turbocharger. Release the clip and
disconnect the control rod.
8 Do not attempt to dismantle the
turbocharger any further. If the unit is thought

12.2 Turbocharger heat shield

12.3 Exhaust flange connection nuts

12.5 Turbocharger oil return union

12.6 Undo the nuts and separate the
turbocharger from the exhaust manifold

Removal
1 Remove the exhaust manifold, together
with the turbocharger assembly, as described
in Section 15.
2 With the assembly on the bench, unbolt the
turbocharger heat shield (see illustration).
3 Undo the retaining nuts and remove the
exhaust connection flange and gasket from
the turbocharger (see illustration).
4 Undo the union and remove the oil feed
pipe along with the sealing washers which are
fitted on each side of the pipe union (see
illustration).
5 Unscrew the retaining bolts and remove the

12.4 Turbocharger oil feed pipe union

4C.12

Fuel and exhaust systems - diesel engine

14.17a Remove the rear section of the
manifold. .

.

Note: New manifold retaining nuts will be
required on refitting
Note: The intercooler is only fitted to the
Y17DT engine.

9 Disconnect the vacuum hose from the EGR
solenoid valve, then disconnect the wiring and
unbolt the solenoid valve.
10 Unbolt the rear engine lifting eye.
11 Disconnect the wiring then unbolt the
clamp and remove the charge pressure sensor.
12 Place a suitable container beneath the oil
filter housing, then unscrew the cover and
remove the filter element.
13 Release the clip and disconnect the oil
return line from the oil filter housing.
14 Unscrew the bolts and remove the three
clamps from the injector lines, then unscrew
the union nuts and remove the lines from the
injection pump and injectors.
15 Unscrew the union bolt and the mounting
bolt securing the oil return line to the cylinder
head, then release the clip and disconnect the
oil return hose.
16 Disconnect the three wiring plugs from
the injection pump.
17 Progressively unscrew the mounting bolts
and nuts, and remove the inlet manifold rear
and front sections from the cylinder head (see
illustrations). Recover the gaskets.

Removal

Refitting

1 Disconnect the battery negative lead (refer
to Disconnectina the batterv in the Reference
Chapter).
2 Remove the air cleaner assembly as
escribed in Section 2.
3 Remove the engine electronic control unit
(ECU) as described in Section 8.
4 ~ o b s e n the clip and disconnect the
crankcase ventilation hose from the left-hand
end of the camshaft cover. Unscrew the
intercooler-to-turbocharger air pipe mounting
bolts, then disconnect the pipe from the
turbocharger and withdraw from the engine.
5 Unscrew the nuts and remove the
starterlalternator wiring harness bracket from
the EGR valve.
6 Loosen the clips and disconnect the charge
air hose from the centre air pipe, then unbolt
the centre air pipe from the inlet manifold.
7 Disconnect the wiring from the glow plugs.
8 Remove the EGR valve and gaskets with
reference to Chapter 40. To do this, unbolt
the pipe then unscrew the studs and bolts,
disconnect the vacuum hose and remove the
valve. Recover the gaskets.

18 Clean the cylinder head and manifold(s)
gasket faces, and fit a new gasket(s) in place.
19 The remainder of the refitting procedure is
a reversal of removal, but tighten all nuts and
bolts to the correct torque setting where
specified. After reconnectingthe battery, have
a dealer reprogram the volatile memories.

14.17b

...and the front section

to be faulty take it to a turbo specialist or
Vauxhall dealer for testing and examination.
They will be able to inform you if the unit can
be overhauled or will need renewing.

Refitting
9 Refitting is the reverse of removal, using
new gaskets and sealing washers, and
tightening the fasteners to their specified
torque settings (where given). Refit the
manifold and turbocharger assembly as
described in Section 15.

-

13 Intercooler
removal and refitting
Note: The intercooler is only fitted to the
Y17DT engine.

Removal
1 The intercooler is located in front of the
lower part of the radiator.
2 Remove the front bumper with reference to
Chapter 11.
3 Carefully unclip the air duct from the front
of the radiator, and lift upwards from behind
the front crossmember.
4 Loosen the clips and disconnect the two air
hoses from the intercooler.
5 Release the retaining clamps and withdraw
the intercooler frorn the front of the radiator.

Refitting
6 Refitting is a reversal of removal.

15.3a Engine oil level dipstick tube upper
mounting bolt.

..

15.3b

...and lower mounting bolts

Note: The intercooler is only fitted to the
Y17DT engine.

Removal
1 The exhaust manifold is removed together
with the turbocharger, then separated on the
bench. First, apply the handbrake, then jack
up the front of the vehicle and support it on
axle stands (see Jacking and vehicle support).
Remove the right-hand front roadwheel and
the inner wheel arch liner for access to the
crankshaft pulley. Remove the engine
compartment undertray.
2 Disconnect the battery negative lead (refer
to Disconnecting the battery in the Reference
Chapter). Remove the air cleaner and ducting
as described in Section 2.
3 Unscrew the upper and lower mounting
bolts and remove the oil level dipstick tube
from the sump. Note the wiring and hose
supports on the tube (see illustrations).
4 Remove the auxiliary drivebelt as described
in Chapter 18. Prior to removal, mark the
direction of rotation on the belt to ensure the
belt is refitted the same way around.
5 At the rear of the alternator, loosen the clips
and remove the brake vacuum pump oil return
hose from the pump and block.

Fuel and exhat~ ssystems
t
- diesel engine 4 0 13

15.6 Exhaust front pipe-to-turbocharger
joint

15.7 Unbolt the turbocharger from the
cylinder block mounting bracket

15.8 Disconnect the oil r e t u r ~hose

6 Unbolt the exhaust front pipe from the
turbocharger, taking care to support the
flexible section (see illustration). Note:
Angular movement in excess of 10" can cause
permanent damage to the flexible section.
Release the mounting rubbers and support
the front of the exhaust pipe to one side.
7 Unscrew and remove the turbocharger
mounting bracket bolt (see illustration).
8 Loosen the clips and remove the
turbocharger oil return hose (see illustration).
9 While counterholding the block adapter with
one spanner, unscrew the domed nut from the
oil feed line union on the block (see illustration).
10 Disconnect the vacuum hose from the
wastegate actuator on the turbocharger (see
illustration).
11 Loosen the clips securing the air intake
pipe to the turbocharger and intercooler (see
illustration), then unscrew the mounting bolt
and remove the air intake pipe.

12 On
models
equipped
with
air
conditioning, disconnect the compressor
wiring plug, undo the compressor mounting
bolts, and move the compressor to one side.
Secure the compressor with cable ties. Do not
open the refrigerant hoses.
13 Undo the three bolts and remove the air
conditioning compressor mounting bracket.
14 Unscrew the nuts securing the oil dipstick
guide tube bracket to the camshaft cover,
then unbolt the guide tube from the block,
release the vacuum hoses and remove the
bracket and guide tube (see illustration).
15 Unscrew the bolt, loosen the clip and
remove the centre charge air pipe.
16 Unbolt the heat shield from the exhaust
manifold (see illustration).
17 Disconnect the wiring from the engine
electronic control unit.
18 Disconnect the crankcase ventilation hose
from the camshaft cover then unscrew the

mounting bolts and disconnect the air intake
pipe from the turbocharger. Also disconnect the
clips and remove the centre charge air hose.
19 Unscrew the oil feed banjo bolt on the
turbocharger and recover the seals.
20 The EGR (exhaust gas recirculation) pipe
is mounted at the left-hand end of the
manrfold. Undo the two retaining bolts, and
recover the gasket (see illustration).
21 Undo the exhaust manifold retaining
nuts/bolts, unscrew and remove the two
manifold studs, and remove the exhaust
manifold.
22 The manifold can now be separated from
the turbocharger as described in Section 12.

15.9 Remove the oil feed pipe from the
cylinder block

15.10 Wastegate actuator vacuum pipe

15.11 Turbocharger air intake pipe

15.14 Remove the oil dipstick guide tube
mounting bolt from the block

15.16 Exhaust manifold heat shield

15.20 EGR pipe flange on the exhaust
manifold

Refitting
23 Refitting is the reverse of removal, but
clean the mating surfaces and renew all
gaskets/sealing washers. Tighten all nuts and
bolts to their specified torques, where given.

4C.14

Fuel and exhaust systems - diesel engine

l
16.5 Exhaust system

7 Front exhaust pipe with flexible
section

2 Catalytic converter
3 Intermediate exhaust pipe

exhaust system, it is wise to inspect the
remaining section. If corrosion or damage is
evident, it may prove more economical to
renew the entire system.

4 Rear silencer
5 Tail pipe

1 The exhaust system is in two sections. The
front section includes the catalytic converter,
oxygen sensor and intermediate pipe. The
rear section consists of the tailpipe and
silencer.
2 Periodically, the exhaust system should be
checked for signs of leaks or damage. Also
inspect the system rubber mountings, and
renew if necessary.
3 Small holes or cracks can be repaired using
proprietary exhaust repair products.
4 Before renewing an individual section of the

5 If either part of the system is to be renewed,
it is important to ensure that the correct
component is obtained (see illustration).
6 To remove the rear tailpipe and silencer,
chock the front wheels then jack up the rear of
the vehicle and support on axle stands (see
Jacking and vehicle support). Loosen the
clamp securing the intermediate pipe to the
tailpipe, then release the rubber mountings
and slide the tailpipe from the intermediate
pipe (see illustrations). If the tailpipe is
rusted onto the intermediate pipe, tap around
the joint with a hammer to free it. Twist the

tailpipe in both directions while holding the
intermediate pipe.
7 To remove the front section of the exhaust,
jack up the front and rear of the vehicle and
support it on axle stands (see Jacking and
vehicle support). Remove the tailpipe and
silencer as described in paragraph 6, then
unbolt the exhaust front pipe from the
turbocharger, taking care to support the
flexible section. Note: Angular movement in
excess of 10" can cause permanent damage
to the flexible section. Recover the gasket.
Release the rubber mountings and withdraw
the exhaust from under the vehicle (see
illustration).
8 Refitting is a reversal of removal, but renew
all gaskets and tighten the clamp and front
pipe flange nuts to the specified torque,
where given.

16.6a Tailpipe-to-intermediatepipe
exhaust clamp

16.6b One of the tailpipe rubber
mountings

16.7 Exhaust front section rubber
mountings

-

16 Exhaust system
general information,
removal and refitting

Component renewal
General information


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