Compression, Check
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
2. |
Disconnect battery
• |
Detach ground connection from ground terminal
|
|
4. |
Remove fuel pump relay
• |
Detach relay holder cover
|
• |
Attach relay holder cover
|
|
|
|
5. |
Detach vacuum line
• |
Unscrew 2x bolts (arrows)
|
• |
Detach 2x hose vacuum unit to vacuum line
|
|
|
|
6. |
Detach wiring harness
• |
Disconnect 4x wiring harness plugs for injector (2)
|
|
|
|
7. |
Detach 4x oil leak line (2) from injectors
Note: The oil leak line
must not be detached from the fuel return damping case. It if is
detached, it must be replaced.
• |
Release 4x retaining clamp (3) from injector in direction of
arrow
– |
Pull off oil leak line
Note: Close 4x
injectors with suitable
Sealing plug
1)
|
|
• |
Unclip 2x oil leak line from bracket (1)
|
|
|
|
8. |
Detach 4x high pressure line - accumulator to injector
Important: When releasing the
retaining nut, counterhold with open-ended wrench against the
injector
|
• |
Unscrew 8x union nut (1)
Note: Close opened fuel
connections with appropriate plugs
1)
|
|
|
|
9. |
Remove 4x injector
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. |
Connect battery
• |
Attach ground connection to ground terminal
|
|
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. |
Check compression of cylinder 1
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.
• |
2nd mechanic is required.
|
• |
Start engine for approx. 4 seconds
Note: Engine speed at
least 200 rpm.
|
• |
Detach compression plotter
|
• |
Remove EN-46791 , EN-46783
|
|
13. |
Repeat the test procedure on cylinders 2, 3 and 4
|
14. |
Compare compression values
• |
Maximum pressure differential 150 kPa (1.5 bar)
|
|
Install
15. |
Disconnect battery
• |
Detach ground connection from ground terminal
|
|
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.
|
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. |
Install 4x new high pressure line
• |
Tighten 4x retaining nut (M14) 23
Nm
|
• |
Tighten 4x retaining nut (M12) 23
Nm
|
|
19. |
Attach wiring harness
• |
Connect 4x injector wiring harness plug
|
|
20. |
Attach 4x oil leak line to injector
• |
Clip 4x oil leak line into injector
|
• |
Clip 2x oil leak line in bracket
|
|
21. |
Attach vacuum line
• |
Attach 2x vacuum hose, vacuum unit to vacuum line
|
|
22. |
Install fuel pump relay
• |
Detach relay holder cover
|
• |
Attach relay holder cover
|
|
23. |
Connect battery
• |
Attach ground connection to ground terminal
|
|
Important: Wear protective
goggles and protective gloves.
|
24. |
Fuel System, Check for Leaks
• |
Start engine.
Note: Check fuel system
for escaping fuel.
|
|
26. |
Program volatile memories
|
1 ) protective caps are available in the opel parts
catalogue under catalogue number 45 06 154 / part number 9201697/
|