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Repair engine using a short-block > < Check engine oil pressure

Corsa C

Engine Pressure Loss, Check - Diesel Engine

  Remove

1.   Condition: engine must be at operating temperature (min. oil temperature 80° )
2.   Open bonnet
3.   Disconnect battery
•   Ground cable from ground terminal
– Remove nut
4.   Remove engine cover.
•   Unclip 4x
5.   Remove air cleaner housing (1)
•   Detach wiring harness of mass air flow meter (3)
– Disconnect wiring harness plug
– Undo clip
•   Release clamp (4)
•   Remove bolt (2)
•   Detach front intake hose (5)
Object Number: 2406279 Size: DEFAULT


6.   Remove air intake pipe (1)
•   Unscrew 2 bolts (arrows)
•   Unclip wiring harness
•   Unclip fuel line from bracket
•   Detach engine vent hose
– Release 2x clamp
Object Number: 2406298 Size: DEFAULT


7.   Detach oil leak line
Important:   Seal the leak oil line connection to the injector with closure cap from kit (catalogue number 45 06 154).
•   Fit 4 retaining clamps (arrows). Remove oil leak line.
Note:   The retaining clamps will be ruined upon removal (overexpansion).
•   Attach 4 closure caps
Object Number: 2406309 Size: DEFAULT


8.   Detach 4 high pressure lines from accumulator to injectors
Important:   Seal the connection of the oil leak line to the injector and accumulator as well as the high pressure lines with closure caps from the kit (catalogue number 45 06 154)
•   Unscrew 8 union nuts (1)
•   Attach 16 closure caps
Object Number: 7361089 Size: DEFAULT


9.   Detach wiring harness of injectors
•   Detach wiring trough from camshaft housing
Note:   Be careful of the ground cable
– Unscrew 3 bolts
•   Disconnect 4 wiring harness plugs from injectors
•   Disconnect camshaft sensor wiring harness plug
10.   Remove 4x injector (2)
Note:   The injectors can only be removed in pairs with the bracket (3) (1st and 2nd cylinder and 3rd and 4th cylinder)
Important:   Seal injector at front with closure cap from kit (catalogue number 45 06 154)
•   Unscrew 2 nuts (1)
•   Attach 4 closure caps
Object Number: 2408369 Size: DEFAULT


11.   Clean 4 injector seats with EN-47632
•   Loosen dirt with brush side (1)
•   Remove dirt with sponge side (2)
Object Number: 7361090 Size: DEFAULT


12.   Unscrew timing case closure bolt (1)
•   Unscrew torx bolt
Object Number: 3447388 Size: DEFAULT


13.   Remove camshaft sensor
•   Remove bolt (1)
Object Number: 7361091 Size: DEFAULT


14.   Set engine to 1st cylinder TDC
•   Turn the crankshaft in the direction of engine rotation at the bolt of the ribbed V-belt drive disc flange until the rear edge of the elevation for the camshaft sensor aligns with the front edge of the camshaft sensor installation opening (1)
•   Affix a guide mark on the timing case and 4 on the camshaft drive gear bolt (2)
Object Number: 7361092 Size: DEFAULT


15.   Install camshaft sensor
•   Tighten bolt
– Replace seal ring
16.   Remove coolant compensation tank cap
17.   Remove oil filler port closure cap
18.   Remove oil dipstick
19.   Calibrate pressure loss gauge
20.   Engage 4th gear; apply handbrake
21.   Install EN-46782 (1) with adapter EN-46783 (2) in conjunction with 2nd cylinder injector in 1st cylinder
•   Tighten nut 20 Nm
22.   Attach pressure loss gauge to adapter EN-46783
Object Number: 7361093 Size: DEFAULT


23.   Check 1st cylinder pressure loss
24.   Remove EN-46782 with adapter EN-46783
•   Unscrew nut
25.   Install EN-46482 with adapter EN-46783 in 3rd cylinder
•   Install EN-46482 with adapter EN-46783 in conjunction with 4th cylinder injector
•   Tighten nut 20 Nm
26.   Put vehicle into neutral
27.   Run engine 180° KW
28.   Engage 4th gear
29.   Check 3rd cylinder pressure loss
30.   Remove EN-46782 with adapter EN-46783
•   Unscrew nut
31.   Install EN-46482 in 4th cylinder
•   Install EN-46482 in conjunction with 3rd cylinder injector
•   Tighten nut 20 Nm
32.   Put vehicle into neutral
33.   Run engine 180° KW
34.   Engage 4th gear
35.   Check 4th cylinder pressure loss
36.   Remove EN-46782
•   Unscrew nut
37.   Install EN-46482 in 2nd cylinder
•   Install EN-46482 in conjunction with 1st cylinder injector
•   Tighten nut 20 Nm
38.   Put vehicle into neutral
39.   Run engine 180° KW
40.   Engage 4th gear
41.   Check 2nd cylinder pressure loss
42.   Remove EN-46782
•   Unscrew nut
43.   Close coolant compensation tank cap

  Install

44.   Fit oil filler port closure cap
45.   Install oil dipstick
46.   Fasten timing case closure bolt
•   Use new gasket
47.   Insert gasket in injector shaft 4x
48.   Install 4 injectors
Note:   Injectors can only be installed in pairs (1st and 2nd cylinder / 3rd and 4th cylinder)
•   Detach 4 closure caps
•   Replace 4 gaskets
•   Tighten 2 nuts
49.   Attach wiring harness of injectors
•   Connect 4 injector wiring harness plugs
•   Connect camshaft sensor wiring harness plug
•   Attach wiring trough to camshaft housing
Note:   Be careful of the ground cable.
– Tighten 3 bolts
50.   Attach 4 high pressure lines from accumulator to injectors
•   Attach 16 closure caps
•   Tighten 8 union nuts 24 Nm
51.   Attach oil leak line
•   Detach 4 closure caps
52.   Install air intake manifold
•   Attach engine vent hose
– Fasten clamp
•   Clip fuel line into bracket
•   Tighten clamp
•   Tighten 2 bolts
•   Clip in wiring harness (2x)
53.   Install air cleaner housing
•   Tighten bolt
•   Tighten clamp
•   Attach wiring harness of mass air flow meter
– Connect wiring harness plug
– Fasten clip
54.   Install engine cover.
•   Clip in 4x
55.   Connect battery
•   Ground cable to ground terminal
– Tighten nuts
56.   Program volatile memories
57.   Close bonnet

Repair engine using a short-block > < Check engine oil pressure