vauxhall Workshop Repair Guides

Vauxhall Astra H Service and Repair Manuals | Workshop Auto Service

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Check engine for leaks > < Compression, Check

Check Engine Pressure Loss in Astra H to J DOHC Diesel Engine: General Repair Instructions

Check engine pressure loss

  Remove

1.   Open bonnet
2.   Remove engine cover (2)
•   Detach oil filler port closure cap (1)
•   Pull off engine cover
Note:   Rubber retainers (3) must remain on engine cover
•   Attach oil filler port closure cap
Object Number: 2412632 Size: DEFAULT


3.   Remove air intake manifold (1)
•   Detach wiring harness
– Release 3x clip
•   Undo 2 clamps
•   Unscrew 2x bolts
Object Number: 2412653 Size: DEFAULT


4.   Remove 4x sheathed glow plug
•   Disconnect 4x wiring harness plug (1) with KM-717
•   Unscrew 4x spark plug (2) with MKM-6104
Object Number: 2412655 Size: DEFAULT


5.   Detach wiring trough (4) from front toothed belt cover (top)
•   Unscrew bolt (2)
•   Detach wiring harness (3)
– Disconnect camshaft sensor wiring harness plug
– Release 2x clip
•   Detach vacuum line (1)
– Release 2x clip
•   Unclip wiring trough in direction of arrow
– Undo clip
Object Number: 3447352 Size: DEFAULT


6.   Detach front toothed belt cover (top) (4)
•   Detach vacuum line (3)
– Unclip 3x clip
•   Unscrew 8x bolts
Note:   Note different bolt lengths
•   Remove camshaft sensor bracket (1)
– Unscrew bolt (2)
Object Number: 3447353 Size: DEFAULT


7.   Remove coolant compensation tank cover (2)
8.   Remove oil filler port closure cap (1)
9.   Remove oil dipstick (3)
Object Number: 2413412 Size: DEFAULT


  Inspect

10.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC"
•   Marks (1) must align with each other
11.   Install pressure loss tester
•   in conjunction with connection piece KM-6367
•   Calibrate pressure loss tester
Note:   Follow manufacturer's instructions
Object Number: 2415961 Size: DEFAULT


12.   Engage 4th gear, put the handbrake on
13.   Check pressure loss in cylinder 1
•   Max. pressure difference between the individual cylinders 10% approx.
•   The pressure loss per cylinder should not exceed 25%
•   Check escaping air to localise the damage on:
– intake ducts
– exhaust system
– Coolant compensation tank, oil dipstick guide tube
– oil filler port
– Tapped hole for sheathed glow plug
14.   Detach pressure loss tester
•   in conjunction with connection piece KM-6107
15.   Repeat pressure loss test on cylinders 3, 4 and 2
Note:   Determination of "combustion stroke TDC" by attaching marks to the camshaft sprocket as a guide
Object Number: 2415962 Size: DEFAULT


  Install

16.   Close cover of coolant compensation tank
17.   Install oil filler port closure cap
18.   Install oil dipstick
19.   Install front toothed belt cover (top)
•   Tighten 8x bolt 9.8 Nm
Note:   Note different bolt lengths
•   Install camshaft sensor bracket
– Tighten bolt 9.8 Nm
•   Attach vacuum line to toothed belt cover
– Clip in 3x clips
20.   Attach wiring trough to front toothed belt cover (top)
•   Attach wiring trough
– Attach clip
•   Tighten bolt 9.8 Nm
•   Attach wiring harness
– Clip in 2x clips
– Connect camshaft sensor wiring harness plug
•   Attach vacuum line
– Clip in 2x clips
21.   Install 4x sheathed glow plug
•   Tighten 4x spark plug with MKM-6104 17.5 Nm
•   Connect 4x wiring harness plugs
22.   Install air intake pipe.
•   Fasten 2x clamp 3.5 Nm
•   Tighten 2x bolts
•   Attach wiring harness
– Clip in 3x clips
23.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
24.   Close bonnet

Check engine for leaks > < Compression, Check