Opel Insignia: Description, Engine Identification, Inspection Procedures

DESCRIPTION

Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process. Descriptions of cleaning, inspection, and assembly processes are included.

ENGINE IDENTIFICATION

Engine may be identified from Vehicle Identification Number (VIN) stamped on a metal tab. Metal tab may be located in different locations depending on manufacturer. Engine identification number or serial number is located on cylinder block. Location varies with each manufacturer.

INSPECTION PROCEDURES

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NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

GENERAL

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Engine components must be inspected to meet manufacturer's specifications and tolerances during overhaul. Proper dimensions and tolerances must be met to obtain proper performance and maximum engine life.

Micrometers, depth gauges and dial indicator are used for checking tolerances during engine overhaul.

Magnaflux, Magnaglo, dye-check, ultrasonic and x-ray inspection procedures are used for parts inspection.

MAGNETIC PARTICLE INSPECTION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Magnaflux & Magnaglo

Magnaflux is an inspection technique used to locate material flaws and stress cracks. Component is subjected to a strong magnetic field. Entire component or a localized area can be magnetized.

Component is coated with either a wet or dry material that contains fine magnetic particles.

Cracks which are outlined by the particles cause an interruption of magnetic field. Dry powder method of Magnaflux can be used in normal lighting and crack appears as a bright line.

Fluorescent liquid is used along with a Black light in the Magnaglo Magnaflux system. Darkened room is required for this procedure. The crack will appear as a glowing line. Complete demagnetizing of component upon completion is required on both procedures. Magnetic particle inspection applies to ferrous materials only.

PENETRANT INSPECTION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Zyglo

The Zyglo process coats material with a fluorescent dye penetrant. Component is often warmed to expand cracks that will be penetrated by the dye. Using darkened room and Black light, component is inspected for cracks. Crack will glow brightly.

Developing solution is often used to enhance results. Parts made of any material, such as aluminum cylinder heads or plastics, may be tested using this process.

Dye Check

Penetrating dye is sprayed on the previously cleaned component. Dye is left on component for 5-45 minutes, depending upon material density. Component is then wiped clean and sprayed with a developing solution. Surface cracks will show up as a bright line.

ULTRASONIC INSPECTION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul processca.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

If an expensive part is suspected of internal cracking, ultrasonic testing is used. Sound waves are used for component inspection.

X-RAY INSPECTION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

This form of inspection is used on highly stressed components. X-ray inspection may be used to detect internal and external flaws in any material.

PRESSURE TESTING

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Cylinder heads can be tested for cracks using a pressure tester. Pressure testing is performed by plugging all but one of the holes of cylinder head and injecting air or water into the open passage.

Leaks are indicated by the appearance of wet or damp areas when using water. When air is used, it is necessary to spray the head surface with a soap solution. Bubbles will indicate a leak. Cylinder head may also be submerged in water heated to specified temperature to check for cracks created during heat expansion.

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