Vauxhall Workshop Service and Repair Manuals

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

  Remove

Remove injection lines – see operation "Injection Lines, Remove and Install".

Remove sheathed glow plugs (1 and 2) – see operation "Sheathed glow plugs, remove and install".

Version with AC: Remove visco-fan – see operation "Visco-fan, Remove and Install".

1. Adjust cylinder to "TDC" – see operation "Timing, Check".

Position guide mark (1) at suitable point on timing case. Guide mark "1st Cylinder TDC" on torsional vibration damper and guide mark on timing case must align.

Make guide markings (arrows) every 120° on torsional vibration damper.

  Remove

Remove oil filler opening cap, coolant compensation tank cap and dipstick.

Caution

The crankshaft is not permitted to rotate during the test procedure. In order to avoid this, engage 1st gear or selector lever position "P" and apply parking brake.

Screw Adapter KM-488 with Connection Piece KM-533-B and connection hose (1) in threaded bore of sheathed glow plugs – tightening torque 22 Nm / 16 lbf. ft.

Connect pressure loss tester to a compressed air system and connect test nozzle (2). Calibrate the compressed air tester by turning the knurled thumb screw (3). Connect test hose to connecting piece.

  Inspect

Max. pressure difference between individual cylinders 10%. Max. cylinder pressure loss should not exceed 25%

For the following components, note any escaping air in order to localise damage: intake ducts, exhaust, coolant compensation tank, dipstick guide tube and sheathed glow plug threaded bores.

Check pressure loss at cylinders 2. to 6. accordingly. Turn crank shaft in accordance with guide markings (arrows) on torsion vibration damper. Guide markings must correspond with guide marking (1) on timing case. Injection order: 1-5-3-6-2-4.

  Remove

Remove Adapter KM-488 and Connection Piece KM-533-B. Uncouple pressure loss tester from compressed air system.