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Contents Wiring diagrams Section: DOHC Petrol Engine All sections

Replace All Cup Tappets Opel Astra G

DOHC Petrol Engine 26 illustrations ~1421 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery
  3. 3. Remove air cleaner housing (5) and air intake manifold (3) • 1 mass air flow meter wiring harness plug (4) • Unclip tank ventilation hose (1) • 1 fastening bolt (2) • 1 clip
  1. 4. Remove air intake manifold
  2. 5. Raise lifting platform
  3. 6. Remove engine splash guard (2) • 4 bolts (1)
  1. 7. Set engine to 60° (measurement l) before TDC • Set crankshaft in direction of engine rotation to 60° (measurement l) before TDC
  1. 8. Lower lifting platform
  2. 9. Remove upper part of toothed belt cover (1) • 2 bolts (2) • Release upper catch (3) • Pull upper part of toothed belt cover upwards by pulling gently on the stalk (arrow)
  1. 10. Remove toothed belt • Mark direction of rotation • Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allan key (1). Fix using KM-6333 (3) – Remove toothed belt
  1. 11. Remove exhaust-side camshaft timing gear • Fit KM-6347 and KM-956-1 (2) to camshaft pulley – Release fixing bolts (3) from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt • Release camshaft timing gear fixing bolt – Hold using KM-6347 – 2 people • Remove KM-6347 – Release fixing bolts • Remove camshaft pulley fixing bolt (4) – Remove camshaft timing gear

Note. The grooves of KM-6347 (arrows) must engage with camshaft timing gear

  1. 12. Detach intake side camshaft pulley • Fit KM-6347 and KM-956-1 to the camshaft pulley – Release fixing bolts from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt • Release camshaft timing gear fixing bolt – Hold using KM-6347 – 2 people • Remove KM-6347 – Release fixing bolts • Remove camshaft timing gear fixing bolt – Remove camshaft timing gear

Note. The grooves of KM-6347 must engage with camshaft timing gear

  1. 13. Remove DIS-ignition module • Remove cover of DIS-ignition module in the direction of the arrow • 2 bolts • remove from spark plugs using KM-6009 (1)

Note. Note arrow on cover

  1. 14. Remove cylinder head cover (1) • Unclip cable channel • Unlock and pull off engine vent pipe • Release 3 bolts (3), pull upwards and fix in this position with adhesive tape • Slacken 6 bolts (2)

Note. Make sure that the front camshaft bearing cover area (arrow) is clean and free from sealant residues

  1. 15. Release camshaft bearing cover, exhaust camshaft • Loosen the camshaft bearing cover in stages, starting with a half to full turn on the central bolts and working outwards in a spiral
  1. 16. Remove exhaust camshaft • Remove the camshaft bearing cover from the cylinder head and take out the camshaft

Note. Note marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes)

  1. 17. Release camshaft bearing cover, intake camshaft • Loosen the camshaft bearing cover in stages, starting with a half to full turn on the central bolts and working outwards in a spiral
  1. 18. Remove intake camshaft • Remove the camshaft bearing cover from the cylinder head and take out the camshaft

Note. Note marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes)

  1. 19. Remove cup tappets • using KM-845 (1) • 16 off

Important. Observe correct assignment

Install

  1. 20. Insert cup tappets • using KM-845 (1) • 16 off • Lightly coat sliding surfaces with oil

Important. Observe correct assignment

  1. 21. Install intake camshaft • Coat with MoS 2 lubricating paste • Insert camshaft • Apply surface sealant (green) to the sealing surface of the guide bearing (arrows) • Install camshaft bearing cover – Tighten the bolts in a spiral, starting at the centre and working outwards – Tightening torque 8 Nm

Note. Note the identification marking on the camshaft bearing cover

  1. 22. Install exhaust camshaft • Coat with MoS 2 lubricating paste • Insert camshaft • Apply surface sealant (green) to the sealing surface of the guide bearing (arrows) • Install camshaft bearing cover – Tighten the bolts in a spiral, starting at the centre and working outwards – Tightening torque 8 Nm

Note. Note the identification marking on the camshaft bearing cover

  1. 23. Install exhaust camshaft seal ring • Using KM-422 (1) press seal ring into camshaft bearing cover - use the camshaft pulley bolt (2) and washer (3)
  1. 24. Install intake camshaft seal ring • Using KM-422 (1) press seal ring into camshaft bearing cover - use the camshaft pulley bolt (2) and washer (3)
  1. 25. Replace cylinder head cap gasket • Place new gasket (1) into cylinder head cap
  1. 26. Remove the spark plug from cylinder 1 • using KM-6363
  2. 27. Fit KM-6354 • Fit KM-6354 (1) – in cylinder 1 spark plug thread

Important. When fitting the cylinder head cover, ensure that the cylinder head gasket does not become detached. If the gasket is not properly fitted, the engine may suffer severe damage.

  1. 28. Position cylinder head cover • Use KM-6354 to lift the cylinder head cover • Have the cylinder head cover positioned at the rear (I) • Carefully press the front of the cylinder head cover down (II) • Remove KM-6354 (1)
  1. 29. Fit cylinder head cap • Remove adhesive tape from 3 screws • Tighten 12 bolts – Tightening torque 8 Nm • Connect engine vent pipe and lock • Clip in cable channel
  2. 30. Fit the spark plug to cylinder 1 • using KM-6363 – Tightening torque 25 Nm
  3. 31. Install DIS-ignition module • 2 bolts • Tightening torque 8 Nm – Place cover on DIS-ignition module
  4. 32. Fit KM-6347 to exhaust-side camshaft timing gear • Initiate camshaft timing gear - observe marks • Insert camshaft timing gear fixing bolt (4) – Do not tighten – Fit KM-6347 and KM-956-1 (2) on camshaft pulley – Release fixing bolts (3) from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt

Note. The grooves of KM-6347 (arrows) must engage with camshaft timing gear

  1. 33. Tighten exhaust-side camshaft timing gear • Hold using KM-6347 – 2 people – Tightening torque 50 Nm + 60° + 15° • Remove KM-6347
  2. 34. Fit KM-6347 to exhaust-side camshaft timing gear • Initiate camshaft timing gear - observe marks • Insert camshaft timing gear fixing bolt – Do not tighten – Fit KM-6347 and KM-956-1 to camshaft pulley – Release fixing bolts from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt

Note. The grooves of KM-6347 must engage with camshaft timing gear

  1. 35. Tighten exhaust-side camshaft timing gear • Hold using KM-6347 – 2 people – Tightening torque 50 Nm + 60° + 15° • Remove KM-6347
  2. 36. Fix camshaft timing gears using KM-6340 • Set camshaft timing gears in such a way that the marks (3) are opposite one another • Fit KM-6340-Left (1) to camshaft timing intake pulley • Insert KM-6340-Right (2)
  1. 37. Set engine to TDC • Set torsional vibration balancer in direction of engine rotation to "1st cylinder TDC position" (1)
  1. 38. Install toothed belt • Position toothed belt – Position toothed belt onto camshaft timing gear outlet – Position toothed belt on camshaft timing gear inlet – Apply tension to the toothed belt tension roller and remove KM-6333
  2. 39. Remove KM-6340
  3. 40. Turn crankshaft 720° • 2 revolutions in direction of engine rotation • Set toothed belt drivewheel to mark "1st cylinder TDC position" (1)
  1. 41. Fix camshaft timing gears using KM-6340 • Insert KM-6340-Left (1) • Insert KM-6340-Right (2)

Note. The marks (3) on the camshaft timing gears must be aligned - otherwise remove toothed belts and refit

  1. 42. Remove KM-6340
  2. 43. Fit upper part of ribbed belt over • 2 bolts – Tightening torque 6Nm

Note. Check for correct engagement

  1. 44. Fit air intake manifold pipe
  2. 45. Install air cleaner housing and air intake manifold • Place 1 mass air flow meter wiring harness plug • Clip in tank ventilation hose • 1 fastening bolt • 1 clip – Tightening torque 3.5Nm
  3. 46. Connect battery
  4. 47. Programme transient memory
  5. 48. Close bonnet

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