Check Engine Pressure Loss — Opel Astra H (2004-2011)

Check Engine Pressure Loss Opel Astra H

Note. Engine at operating temperature (oil temperature >= 80 °C).

1. Remove air filter housing with mass air flow meter • Detach mass air flow meter wiring harness plug (3) • Detach air intake hose from air intake pipe – Release clamp (2) • Unscrew bolt (1)

Note. Seal air intake pipe at turbocharger

7. Detach charge air deflection pipe • Unscrew 4x bolts (1) • Unclip vacuum line from bracket (2) • Remove charge air deflection pipe

8. Remove fastening bolts (1) and remove top front toothed belt cover from rear toothed belt cover

9. Disconnect wiring harness plug (2) from ignition module (4)
10. Detach ignition module cover (1) in direction of arrow
11. Remove ignition module fastening bolts and detach ignition module from spark plugs using KM-6009 (3)

12. Remove spark plugs • using KM-194-E
13. Remove oil filler opening closure cap
14. Remove coolant expansion tank closure cap
15. Remove oil dipstick
16. Turn crankshaft in direction of engine rotation to "Cylinder no.1 TDC" mark using toothed belt drive gear fastening bolt

Note. At the same time, the notches on the camshaft sprockets must align with the marks on the cylinder head cover

Note. Follow manufacturer's instructions

19. Screw connecting piece into spark plug hole of cylinder no.1 and connect pressure loss tester to connecting piece

Note. Follow manufacturer's instructions

Important. The crankshaft is not permitted to rotate during the test procedure. In order to avoid this, engage 1st gear and apply parking brake

20. Read off percentage pressure loss from tester. At the same time, listen for any sound of compressed air escaping from the intake manifold, the exhaust system or the crankcase and any bubble formation in the coolant expansion tank. Max. pressure difference between the individual cylinders is approx. 10% The max. pressure loss for one cylinder must not exceed 25%
21. Check pressure loss at cylinders 3, 4 and 2 using same method. Move piston of cylinder to be tested to "Ignition TDC" position. Ignition sequence: 1-3-4-2. Determine "TDC" position by putting positioning marks (1), (2), (3) and (4) on a camshaft sprocket.
22. Continue to turn camshaft 180° in direction of engine rotation (corresponding to 90° on camshaft pulley) until positioning marks on camshaft pulley align with cylinder head cover. Determine "TDC" position for 4th and 2nd cylinders accordingly. Turn crankshaft slowly and uniformly.

23. Install spark plugs with KM-194-E 25 Nm
24. Connect ignition module to spark plugs and attach to cylinder head 8 Nm
25. Attach ignition module cover to cylinder head cover
26. Connect wiring harness plug to ignition module
27. Install oil filler opening closure cap
28. Install coolant expansion tank closure cap
29. Install oil dipstick
30. Attach top front toothed belt cover to rear toothed belt cover 6Nm
31. Install air cleaner housing with mass air flow meter • Insert air cleaner housing • Attach air intake hose to air intake pipe – Fasten clamp • Screw in bolt • Connect mass air flow meter wiring harness plug
32. Install charge air deflection pipe • Screw in 4x bolts • Clip vacuum line into bracket
33. Fit charge air hose • Insert charge air hose • Attach 2x clamps
34. Remove seal from turbocharger air intake pipe
35. Attach engine vent hose to cylinder head cover • Fasten clamp
36. Attach air intake pipe to turbocharger • Fasten clamp
37. Attach air intake pipe to air intake hose • Fasten clamp
38. Screw in bolt
39. Attach bulkhead cover plate insulation 4 Nm .

Check Engine Pressure Loss Opel Astra H