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Checking Engine Pressure Loss Opel Meriva A

DOHC Diesel Engine 7 illustrations ~489 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery • Detach ground cable
  3. 3. Remove air intake hose • Release 2x clamp
  1. 4. Detach engine management wiring harness • Disconnect 3x wiring harness plugs (arrows) – Engine control unit – 2x combination plugs • Expose wiring harness
  2. 5. Slacken air intake pipe (1) • Detach engine vent hose • Unscrew 2x bolt • Unclip wiring harness
  1. 6. Remove engine control unit (1) • Disconnect wiring harness connector. • Unscrew 2x bolt • Unscrew 2x nut
  1. 7. Disconnect 4x injector wiring harness plugs (2)
  2. 8. Detach engine control unit bracket (1) • Unscrew 4x bolt
  1. 9. Separate 4x sheathed glow plug wiring harness plugs (1) • Use KM-717
  2. 10. Remove 4x sheathed glow plugs (2) • Use MKM-6104
  1. 11. Raise vehicle all the way
  2. 12. Remove right engine splash guard • Unscrew 3x bolt (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 cylinder no.1 must face upward - cam position can be checked through the oil filler port. If cylinder no.1 cams are not facing upward, turn the crankshaft one revolution to "Cylinder no.1 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. Continue rotating crankshaft by 180° to positioning mark or TDC mark

Install

  1. 21. Fit coolant compensation tank cap, oil filler port closure cap and oil dipstick
  2. 22. Tighten 4x sheathed glow plugs 17,5 Nm • Use MKM-6104
  3. 23. Connect 4 injector wiring harness plugs
  4. 24. Attach engine control unit bracket • Tighten 4x bolt
  5. 25. Connect 4 injector wiring harness plugs
  6. 26. Attach engine control unit • Tighten 2x bolts 9,8 Nm • Tighten 2x nuts 9,8 Nm • Connect wiring harness plug
  7. 27. Attach air intake pipe • Tighten 2 bolts • Attach vent hose • Clip wiring harness into position
  8. 28. Attach engine management wiring harness • Route wiring harness • Connect 3 wiring harness plugs
  9. 29. Install air intake hose. • Attach 2x clamps 5 Nm
  10. 30. Connect battery • Ground cable
  11. 31. Close bonnet
  12. 32. Program volatile memory

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