Check Engine Pressure Loss 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. Loosen front right wheel
4. 4. Raise vehicle by half-height
5. 5. Remove front right wheel
6. 6. Raise vehicle by half-height
7. 7. Remove ribbed V-belt cover • Remove 4 body-bound rivets (arrows)

8. 8. Lower vehicle by full height
9. 9. Remove air cleaner housing
10. 10. Remove resonator (1) • Unscrew 2x bolt

11. 11. Remove charge air hose (1) • Detach from intercooler – Loosen clamp • Detach from charge air pipe – Loosen clamp

12. 12. Detach wiring harness for engine management • Detach wiring harness plug of camshaft sensor (2) • Disconnect 4 injector wiring harness plugs (1)

13. 13. 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)

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

Note. Retaining clamps are not detached

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

16. 16. 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)

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

18. 18. Unscrew timing case closure bolt (1)

19. 19. Remove camshaft sensor • Disconnect wiring harness plug • Remove bolt (1)

20. 20. Set engine to 1st cylinder TDC • Use the flange bolt of the torsional vibration damper to turn the crankshaft in the direction of engine rotation until the rear edge of the camshaft sensor elevation aligns with the front edge of the installation opening of the camshaft sensor (1).

Note. 2nd mechanic

21. 21. Apply guide marks • Apply 1 guide mark to the timing case and 4 to the camshaft drive gear bolt (2)

22. 22. Install camshaft sensor • Replace seal ring • Tighten bolt 7 Nm
23. 23. Remove coolant compensation tank cap
24. 24. Remove oil filler port cap
25. 25. Remove dipstick
26. 26. Calibrate pressure loss gauge
27. 27. Engage 4th gear and apply handbrake
28. 28. Install EN-46782 (1) in 1st cylinder • Attach EN-46783 (2) to EN-46782 – Tighten nut 20 Nm • Install EN-46782 with a new gasket

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

29. 29. Attach pressure loss tester (2) to EN-46783 (1)

30. 30. Check 1st cylinder pressure loss • Max. pressure difference between individual cylinders - approx. 10% • Pressure loss per cylinder should not exceed 25% • Check air loss through damage localisation at – Intake ports – Exhaust system – Coolant compensation tank – Dipstick guide tube – Oil filler port
31. 31. Detach pressure loss tester from 1st cylinder • Remove EN-46782 and 2nd cylinder injector – Unscrew nut
32. 32. Attach pressure loss tester to 3rd cylinder • Install EN-46482 together with 4th cylinder injector – Tighten nut 20 Nm
33. 33. Allow engine to idle
34. 34. Turn engine 180° crank angle • Use flange bolt of torsional vibration damper to turn crankshaft in direction of engine rotation

Note. Note guide mark!

35. 35. Engage 4th gear
36. 36. Check 3rd cylinder pressure loss
37. 37. Detach pressure loss tester from 3rd cylinder • Remove EN-46782 and 4th cylinder injector – Unscrew nut
38. 38. Attach pressure loss tester to 4th cylinder • Install EN-46482 together with 3rd cylinder injector – Tighten nut 20 Nm
39. 39. Allow engine to idle
40. 40. Turn engine 180° crank angle • Use flange bolt of torsional vibration damper to turn crankshaft in direction of engine rotation

Note. Note guide mark!

41. 41. Engage 4th gear
42. 42. Check 4th cylinder pressure loss
43. 43. Detach pressure loss tester from 4th cylinder • Remove EN-46782 and 3rd cylinder injector – Unscrew nut
44. 44. Attach pressure loss tester to 2nd cylinder • Install EN-46482 together with 1st cylinder injector – Tighten nut 20 Nm
45. 45. Allow engine to idle
46. 46. Turn engine 180° crank angle • Use flange bolt of torsional vibration damper to turn crankshaft in direction of engine rotation

Note. Note guide mark!

47. 47. Engage 4th gear
48. 48. Check 2nd cylinder pressure loss
49. 49. Detach pressure loss tester from 2nd cylinder • Remove EN-46782 and 1st cylinder injector – Unscrew nut
50. 50. Allow engine to idle

Install

51. 51. Install coolant compensation tank cap
52. 52. Attach oil filler port cap
53. 53. Insert dipstick
54. 54. Tighten timing case closure bolt • Use new gasket
55. 55. Install 4 injectors • Replace 4 injector shaft seal rings • Replace 4 injector seal rings (1) • Tighten 2 nuts 20 Nm

56. 56. Attach 4 high pressure lines • Use new high pressure lines • Tighten 4 union nuts (M14) 28 Nm • Tighten 4 union nuts (M12) 24 Nm
57. 57. Attach 4x oil leak line • Release 4 retaining clamps
58. 58. Attach wiring harness for engine management • Connect 4 injector wiring harness plugs • Connect wiring harness plug of camshaft sensor
59. 59. Fit charge air hose • Tighten 2x clamp 3.5 Nm
60. 60. Install resonator • Tighten 2x bolt
61. 61. Install air cleaner housing
62. 62. Install fuel pump relay • Install K16 relay • Attach the relay holder cover
63. 63. Raise vehicle by full height
64. 64. Install ribbed V-belt cover • Install 4x body-bound rivets
65. 65. Lower vehicle by half height
66. 66. Mount front right wheel
67. 67. Lower vehicle by half height
68. 68. Tighten front right wheel 110 Nm
69. 69. Connect battery • Attach ground clamp to ground terminal – Tighten nut 5.5 Nm
70. 70. Program volatile memories
71. 71. 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)