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Contents Wiring diagrams Section: DOHC Diesel Engine All sections

Check Engine Pressure Loss Opel Astra G

DOHC Diesel Engine 8 illustrations ~501 words

Remove

  1. 1. Open bonnet
  2. 2. Remove bonnet (2) • Remove oil filler cap (1) • Pull off engine cover – 3 off • Replace oil filler cap

Note. Rubber retainers (3) must remain in cover

  1. 3. Remove air intake manifold (1) • Unclip wiring harness – 3 clips • 2 clips • 2 fastening bolts
  1. 4. Remove sheathed glow plug • 4 wiring harness plugs (1) – using KM-717 • 4 sheathed glow plugs (2) – using MKM-6104
  1. 5. Remove cable duct (4) from upper section of toothed belt cover • 1 fastening bolt (2) • Camshaft sensor wiring harness plug with wiring harness (3) – 2 clips • Vacuum line (1) – 2 clips • Unclip cable duct in direction of arrow – 1 clip
  1. 6. Remove upper part of toothed belt cover (3) • 8 fastening bolts • Remove camshaft sensor bracket (1) – 1 fastening bolt (2)

Note. Note different bolt lengths

  1. 7. Remove coolant compensating reservoir cap (2)
  2. 8. Remove oil filler cap (1)
  3. 9. Remove dipstick (3)

Inspect

  1. 10. Turn crankshaft in direction of engine rotation to "1st cylinder TDC". • Marks (1) must be aligned
  2. 11. Install pressure loss tester • together with connecting piece KM-6367 • Calibrate pressure loss tester

Note. Follow manufacturer's instructions

  1. 12. engage 4th gear, pull on handbrake
  2. 13. Check pressure loss in cylinder 1 • Max. pressure difference between the individual cylinders 10% approx. • The pressure loss should not exceed 25% per cylinder • To locate the damage, check for escaping air: – from the intake channels – from the exhaust system – from the coolant compensating reservoir and the dipstick guide tube – Oil filler opening – from the threaded holes for the sheathed glow plugs
  3. 14. Remove pressure loss tester • together with connecting piece KM-6107
  4. 15. Check pressure loss in cylinders 3, 4 and 2

Note. Determine the "ignition TDC" position by applying locating marks to the camshaft pulley

Install

  1. 16. Close the coolant compensating reservoir cap
  2. 17. Replace oil filler cap
  3. 18. Replace dipstick
  4. 19. Install upper part of toothed belt cover • 8 fastening bolts – Tightening torque 9.8 Nm • Install camshaft sensor bracket – 1 fastening bolt – Tightening torque 9.8 Nm

Note. Note different bolt lengths

  1. 20. Mount cable channel on upper part of toothed belt cover • 1 fastening bolt – Tightening torque 6 Nm • Camshaft sensor wiring harness plug with wiring harness – 2 clips • Vacuum line – 2 clips • Clip in cable channel – 1 clip
  2. 21. Install sheathed glow plugs • 4 sheathed glow plugs – using MKM-6104 – Tightening torque 17.5 Nm • 4 wiring harness plugs
  3. 22. Install air intake pipe. • 2 clips – Tightening torque 3.5 Nm • 2 fastening bolts • Clip wiring harness into position – 3 clips
  4. 23. Install engine cover • Remove oil filler cap • Push in engine cover – 3 rubber retainers • Replace oil filler cap
  5. 24. Close bonnet

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