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Contents Wiring diagrams Section: DOHC Diesel Engine All sections

Checking Engine Pressure Loss Opel Combo C

DOHC Diesel Engine 7 illustrations ~503 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery • Detach ground cable
  3. 3. Remove air intake hose • Release 2x clamp
  1. 4. Remove engine management wiring harness • Disconnect 3 wiring harness plugs (arrows) • Expose wiring harness
  2. 5. Loosen air intake pipe (1) • Remove engine vent hose • Unscrew 2 bolts • Unclip wiring harness
  1. 6. Remove engine control unit (1) • Release wiring harness plug in direction of arrow • Unscrew 2 bolts • Unscrew 2 nuts
  1. 7. Disconnect 4 wiring harness plugs, injector (2)
  2. 8. Detach engine control unit bracket (1) • Unscrew 4 bolts
  1. 9. Disconnect 4x wiring harness plug, sheathed glow plug (1) • Use KM-717
  2. 10. Remove 4x sheathed glow plug (2) • Use MKM-6104
  1. 11. Raise vehicle all the way
  2. 12. Remove right engine splash guard • Unscrew 3 bolts (1) • Remove body-bound rivet (arrow)
  1. 13. Remove coolant compensation tank cap, oil filler port closure cap and oil dipstick

Inspect

  1. 14. Set crankshaft to "1st cylinder TDC" following direction of engine rotation • The markings (1) must align

Note. The cams of 1st cylinder must face up - Cam position can be checked via the oil filler port. If 1st cylinder cams do not face up, turn the crankshaft one revolution to "1st cylinder TDC".

  1. 15. Affix guide marking to torsional vibration damper

Note. Guide marking must be exactly 180° across from TDC marking

  1. 16. Attach pressure loss tester • Together with connector KM-6367 • Calibrate pressure loss tester

Note. Follow manufacturer's instructions

  1. 17. Engage 4th gear; apply handbrake
  2. 18. Check 1st cylinder pressure loss • Max. pressure difference between individual cylinders - approx. 10 % • Pressure loss per cylinder should not exceed 25 % • Check the following for air discharge to locate any damage: – Intake ports – Exhaust system – Coolant compensation tank, dipstick guide tube – Oil filler port – Glow plug thread bores
  3. 19. Detach pressure loss tester • Together with connector KM-6107
  4. 20. Repeat pressure loss test for 3rd, 4th and 2nd cylinder

Note. Turn crankshaft 180° to guide marking or TDC marking

Install

  1. 21. Fit coolant compensation tank cap, oil filler port closure cap and oil dipstick
  2. 22. Install 4 sheathed glow plugs 17.5 Nm • Use MKM-6104
  3. 23. Connect 4x injector wiring harness plug
  4. 24. Attach engine control unit bracket • 4 bolts
  5. 25. Connect 4x injector wiring harness plug
  6. 26. Fit engine control unit • Tighten 2 bolts 9.8 Nm • Tighten 2 nuts 9.8 Nm • Connect wiring harness plug
  7. 27. Fasten air intake pipe • Tighten 2 bolts • Install vent hose • Attach wiring harness
  8. 28. Attach engine management wiring harness • Route wiring harness • Connect 3 wiring harness plugs
  9. 29. Install air intake hose. • Fasten 2 clamps 5 Nm
  10. 30. Connect battery • Ground cable
  11. 31. Close bonnet
  12. 32. Calibrate steering angle sensor • Turn on ignition

Note. Rotate the steering wheel one time from its right-hand to its left-hand stop.

  1. 33. Program volatile memory

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