Check Compression Opel Agila A

Warning: When working with the common rail system, wait one minute after switching off the engine. The system relieves the pressure itself.

Important: When working on the fuel system, cleanliness is vital because even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs are only intended to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground clamp from ground terminal – Loosen nut
3. 3. Remove air cleaner housing
4. 4. Disconnect 4 injector wiring harness plugs (1)

5. 5. Place collecting basin underneath.

Important. After the high pressure lines are detached, the openings of the injectors, high pressure pump and pressure chamber must be sealed with protective caps 2)

6. 6. Detach leak oil line • from injectors – Unlatch 4x retaining clamps (1) in the direction of the arrow

Note. Retaining clamps are not detached

7. 7. Detach 4 high pressure lines (1) from the injector pressure chamber • Unscrew 8 union nuts

8. 8. Remove 4 injectors (3) • Detach 2 brackets (2) – Unscrew 2x nut (1) • Remove 4 seal rings (arrows) • Seal 4 injectors with protective caps

Note. Injectors (3) can only be removed with bracket (2) in pairs (1st/2nd cylinder and 3rd/4th cylinder)

9. 9. Clean 4 injectors with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)

10. 10. Attach compression plotter to 1st cylinder • Install EN-46782 (1) in conjunction with EN-46783 (2) in 1st cylinder • Tighten nut 20 Nm • Attach compression plotter (3) to EN-46783

Note. EN-46782 together with an injector can only be installed in pairs (1st/2nd cylinder and 3rd/4th cylinder).

Note. Use a compression plotter with a range of 10-40 bar

Note. Comply with manufacturer's instructions

11. 11. Remove the fuel pump relay (1) • Remove the relay holder cover • Remove relay K16 (1)

12. 12. Connect battery • Attach ground clamp to ground terminal – Tighten nut 5.5 Nm
13. 13. Check 1st cylinder compression • Start the engine for approx. 4 seconds

Note. 2nd mechanic

Note. Engine speed at least 200 rpm

14. 14. Attach compression plotter to 2nd cylinder • Remove EN-46782 from 1st cylinder – Unscrew nut • Install EN-46782 in 2nd cylinder – Tighten nut 20 Nm
15. 15. Check 2nd cylinder compression • Start the engine for approx. 4 seconds

Note. 2nd mechanic

Note. Engine speed at least 200 rpm

16. 16. Attach compression plotter to 3rd cylinder • Remove EN-46782 from 2nd cylinder – Unscrew nut • Install EN-46782 in 3rd cylinder – Tighten nut 20 Nm
17. 17. Check 3rd cylinder compression • Start the engine for approx. 4 seconds

Note. 2nd mechanic

Note. Engine speed at least 200 rpm

18. 18. Attach compression plotter to 4th cylinder • Remove EN-46782 from 3rd cylinder – Unscrew nut • Install EN-46782 in 4th cylinder – Tighten nut 20 Nm
19. 19. Check 4th cylinder compression • Start the engine for approx. 4 seconds

Note. 2nd mechanic

Note. Engine speed at least 200 rpm

20. 20. Detach compression plotter from EN-46783
21. 21. Remove EN-46782 from 4th cylinder • Unscrew nut
22. 22. Compare compression values • Maximum pressure difference 1.5 bar

Install

23. 23. Install 4 injectors • Replace 4 injector shaft seal rings • Replace 4 injector seal rings (1) • Tighten 2 nuts 20 Nm

24. 24. Attach 4 high pressure lines • Use new high pressure lines • Tighten 4 union nuts (M14) 28 Nm • Tighten 4 union nuts (M12) 24 Nm
25. 25. Attach 4x oil leak line • Release 4 retaining clamps
26. 26. Connect 4 injector wiring harness plugs
27. 27. Install air cleaner housing
28. 28. Install fuel pump relay • Install K16 relay • Attach the relay holder cover
29. 29. Program volatile memories
30. 30. Close bonnet.

1

) Protective caps are available in the Opel Parts Catalogue under catalogue number: 45 06 154 / part number: 9201697

2

) (protective caps are available from Opel Parts Catalogue. See catalogue number 45 06 154 / part number: 9201697)