How to Check the Compression Opel Astra H

Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground connection from ground terminal – Slacken nut
3. 3. Remove engine cover
4. 4. Remove fuel pump relay • Detach relay holder cover • Detach relay K13 (1) • Attach relay holder cover

5. 5. Detach vacuum line • Unscrew 2x bolts (arrows) • Detach 2x hose vacuum unit to vacuum line

6. 6. Detach wiring harness • Unscrew 4x bolts (1) • Disconnect 4x wiring harness plugs for injector (2)

7. 7. Detach 4x oil leak line (2) from injectors • Release 4x retaining clamp (3) from injector in direction of arrow – Pull off oil leak line Sealing plug 1) • Unclip 2x oil leak line from bracket (1)

Note. The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.

Note. Close 4x injectors with suitable

8. 8. Detach 4x high pressure line - accumulator to injector • Unscrew 8x union nut (1)

Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector

Note. Close opened fuel connections with appropriate plugs 1)

9. 9. Remove 4x injector • Unscrew 4x nut

Note. If the injectors cannot be reached by hand, use EN-46786 together with KM-328-B . Fit plugs 1) to removed injectors (arrows).

10. 10. Connect battery • Attach ground connection to ground terminal – Tighten nut
11. 11. Attach compression plotter to cylinder 1 • Attach EN-46791 (1) together with EN-46783 (2) • Attach compression plotter (3) to EN-46791 , EN-46783 – Measuring range 1000 to 4000 kPa 10 to 40 bar)

Note. Note manufacturer's provisions.

Inspect

12. 12. Check compression of cylinder 1 • 2nd mechanic is required. • Start engine for approx. 4 seconds • Detach compression plotter • Remove EN-46791 , EN-46783

Note. When compression pressure is checked, 4 cm 3 of fuel will leak out of the open accumulator fuel connections. Catch this fuel with a cloth.

Note. Engine speed at least 200 rpm.

13. 13. Repeat the test procedure on cylinders 2, 3 and 4
14. 14. Compare compression values • Maximum pressure differential 150 kPa (1.5 bar)

Install

15. 15. Disconnect battery • Detach ground connection from ground terminal – Slacken nut
16. 16. Cleaning work

Note. Use EN-47632 (1) to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and clean the injector seat by turning. Finish by cleaning with the fine fleece.

17. 17. Install 4x injector • Replace 4x seal rings • Tighten 4x nut 32 Nm

Important. High-pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.

18. 18. Install 4x new high pressure line • Tighten 4x retaining nut (M14) 23 Nm • Tighten 4x retaining nut (M12) 23 Nm
19. 19. Attach wiring harness • Tighten 4x bolts • Connect 4x injector wiring harness plug
20. 20. Attach 4x oil leak line to injector • Clip 4x oil leak line into injector • Clip 2x oil leak line in bracket
21. 21. Attach vacuum line • Attach 2x vacuum hose, vacuum unit to vacuum line • Tighten 2x bolt 9 Nm
22. 22. Install fuel pump relay • Detach relay holder cover • Install relay K13 • Attach relay holder cover
23. 23. Connect battery • Attach ground connection to ground terminal – Tighten nut

Important. Wear protective goggles and protective gloves.

24. 24. Fuel System, Check for Leaks • Start engine.

Note. Check fuel system for escaping fuel.

25. 25. Attach engine cover
26. 26. Program volatile memories
27. 27. Close bonnet

1

) protective caps are available in the opel parts catalogue under catalogue number 45 06 154 / part number 9201697/