Subject: New 1.7 Litre Diesel Engine
Vehicles: KADETT-E/ASTRA/BELMONT, VECTRA/CAVALIER
As of January 1989, the new
1.7 Ltr. diesel engine will be offered as part of the existing
Kadett-E/Astra/Belmont and Vectra/Cavalier engine range. It replaces the 1.6
Ltr. diesel engine. The 17 D engine has been specifically developed with
optimal performance, consumption and exhaust emission in mind. The 17 D engine
is a further development of the 16 DA engine, and therefore, due to the use to
a large extent of the same components, all of the labour operations already
described for the 16 DA engine apply to the 17 DA engine.
Changes from the 16 DA engine:
see the Product Description Brochures, "Vectra/Cavalier" and
"Model Year 1989 1/2".
The newly tuned injection
pumps with automatic cold start accelerator and electronic cut-off being
introduced reduce the "blue smoke" phase after a cold start.
To improve the cold start
performance of the CAV injection system, a filter assembly with submerged pipe
is being introduced.
In addition, the pre-heater
system with self-diagnosis taken from the 2.3 Ltr. diesel engine reduces the
cold start time by 50%.
Important Notes
The Vectra/Cavalier 1.7 D and
Kadett-E/Astra/Belmont 1.7 D will be introduced into the next Service
Instructions microfiches. Important operations can be found in the
Kadett-E/Astra/Belmont Service Instructions, 4th Revised Edition (Microfiche
III-Group J: Diesel Engines), deviating Technical Data are in this Bulletin
starting on page 4.
The Checking and Adjusting
Operations for the Lucas CAV pump (page 3) differ from those for the Bosch
injection pump.
When removing or installing
the Lucas CAV pump, the dust screen set on the pump shaft should always be
replaced.
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Engine Checking and
Adjusting Operations (Bosch
Injection Pump)
Adjusting operations: see
KADETT-E/ASTRA/BELMONT "Service Instructions".
Adjusting values: see
"Technical Data", page 4 of this Bulletin.
Idle Speeds, Adjust.
Vehicles with manual
transmission:
Lower idle speed- lower
arrow.
Upper idle speed- upper
arrow.
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Vehicles with automatic
transmission:
Lower idle speed- lower
arrow.
Upper idle speed- upper
arrow.
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Engine Checking and
Adjusting Operations (Lucas CAV
Injection Pump)
Adjusting operations: see
Kadett-E/Astra/Belmont "Service Instructions".
Adjusting values: see
"Technical Data", page 4 of this Bulletin.
Idle Speeds, Adjust.
Lower idle speed- lower
arrow.
Upper idle speed- upper
arrow.
1) Closure plug for
measuring tool installation
2) Manufacturer's
identification plate
3) Adjusting value specific
for individual pump
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Adjustment of Injection
Pump, Check and Adjust.
Unscrew closure plug (1,
illus. C 9882).
Screw on Measuring Tool
KM-690 with Dial Gauge MKM-571-B (range 10 mm/0.39 in.).
Carry out checking and
adjusting operation.
Unscrew measuring tool with
dial gauge.
Screw in closure plug.
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Mechanically Controlled
Injection System
Identification / Data Engine 17
D 17 D
Injection pump Bosch Lucas
CAV
for
MT VE 4/9F 2300 R 313 OP 02 DPC
R8443 B55 OA
for
AT VE 4/9F 2300 R 313/1 -------------------
Filter F3/DBS
1 WG/124 F3/DBS 1 WG/124
Injector DN
OSD 292 BDN OSD C 6751 C
RDN
OSD C 6751 C
Opening pressure
new 135
+ 8 bar 135 + 8 bar
run-in 130
+ 8 bar 130 + 8 bar
Identification 130 130
Beginning of delivery at idle
speed 2° to 4° BTDC 2° to 4° BTDC
Static beginning of delivery
BTDC 0.85
± 0.05 mm * X ± 0.30 mm **
Lower idle speed in min-1 820
to 880 820 to 880
Upper idle speed in min-1 5500
to 5600 5500 to 5600
Pre-heater system, voltage in
volts 12 V 12 V
Relay 90
196 015 / 12 38 592 90 196 015 / 12 38 592
Glow plug 90
210 824 / 12 14 306 90 201 005 / 12 14 306
* Adjustment and checks
must be caried out when engine is cold (room temperature).
** X = Adjusting value
specific for individual pump, embossed on pump lever.
Recommended Torque Values 17
D
Torque
Designation Nm (kpm)
Eliminator (crankcase forced
ventilation) to cylinder block.................... 15 (1.5)
Starter to cylinder block.......................................................................... 45 (4.5)
Drive disc to crankshaft........................................................................... 60 (6.0)
4)
Intake manifold to cylinder
head............................................................. 22 (2.2)
Exhaust manifold to cylinder
block......................................................... 22 (2.2)
Glow plug in cylinder head..................................................................... 20 (2.0)
Injector bracket to cylinder
head............................................................. 70 (7.0)
Injection pump bracket to
cylinder head................................................. 25 (2.5)
Alternator bracket to cylinder
block........................................................ 25 (2.5)
Right engine mounting bracket
to cylinder block.................................... 50 (5.0)
Right engine mounting bracket
to damping block................................... 40 (4.0)
Power steering fluid pump
bracket to cylinder block.............................. 40 (4.0)
Crankshaft pulley to
crankshaft gear....................................................... 20 (2.0)
Crankshaft bearing cover to
cylinder block............................................. 50 (5.0)
6)
Con-rod bearing cover to
con-rod........................................................... 35 (3.5)
6)
Camshaft housing and cylinder
head to cylinder block........................... 25 (2.5) 5)
Oil drain plug to oil pan........................................................................... 45 (4.5)
Oil pressure switch to oil
pump............................................................... 40 (4.0)
Oil filter to oil pump................................................................................ 15 (1.5)
Oil pump housing to cylinder
block........................................................ 6 (0.6)
Oil pan to cylinder block.........................................................................
5 (0.5) 7)
Flywheel to crankshaft............................................................................ 65 (6.5)
3)
Temperature sensor in
thermostat housing.............................................. 11 (1.1)
Thermostat housing to cylinder
head....................................................... 15 (1.5)
Vacuum pump to camshaft
housing......................................................... 28 (2.8)
Closure plug to oil pump
safety valve..................................................... 30 (3.0)
Water pump to cylinder block................................................................. 25 (2.5)
Recommended Torque Values
(Continued) 17
D
Torque
Designation Nm (kpm)
Toothed belt drive pinion and
crankshaft pulley to crankshaft............... 130 (13.0) 1)
Camshaft gear to camshaft....................................................................... 75 (7.5)
2)
Gear (assembly) to injection
pump.......................................................... 25 (2.5)
Toothed belt tensioning roller
to cylinder block...................................... 25 (2.5)
Toothed belt guide pulley to
cylinder block............................................ 50 (5.0)
Cylinder head cover to
cylinder head........................................................ 8 (0.8)
Cylinder head to cylinder
block............................................................... 25 (2.5)
5)
1) Then a further 45° + 5°. 2) Then a further 60° + 5°.
3) Then a further 30° + 15°. 4) Then a further 30°.
5) In four stages; 25 Nm + 90° + 90° + 45°. 6) Then a further 45° + 15°.
7) Insert with Sealing
Compound (Parts No. 90 094 714 / Catalogue No. 15 03 166).
Note
When angles are given, tighten
bolts with appropriate torque and then turn to the given angle.
Only use bolts once; even when
microencapsulated, always use new bolts.
Time Allowance
The operations that deviate
from those for the 16 DA engine will be published in the
"Kadett-E/Astra/Belmont Time Allowance" microfiche.
