How to Replace the Cup Tappets Opel Astra H

Important: When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

Remove

1. 1. Remove air cleaner housing
2. 2. Remove engine cover
3. 3. Remove air intake manifold (1) • Release clamp

4. 4. Disconnect battery • Detach earth connection from earth terminal – Slacken nut
5. 5. Remove battery • Detach positive terminal (3) from positive pole – Slacken nut • Remove bracket 1) – Unscrew bolt (2)

6. 6. Remove battery support. • Unclip control unit of pre-heating system (4) • Unclip coolant hose bracket (5) • Detach wiring harness – Unclip 2x from battery support (1) • Unclip wiring harness plug (3) • Unscrew 3x bolts (2)

7. 7. Raise vehicle by half its height
8. 8. Detach wiring harness from engine control unit • Release and unplug wiring harness plug (1) from engine control unit • Unclip wiring harness from bracket • Unclip 3x wiring harnesses from engine

9. 9. Lower vehicle by half its height
10. 10. Disconnect upper engine timing wiring harness • Detach fuse carrier cover • Detach positive cable (1) from fuse carrier – Unscrew nut • Release and unplug wiring harness plug (2) • Unclip wiring harness and expose

Note. Mark installation position

11. 11. Detach fuel return line (1) from injector • 4x from injector – Release retaining clamps (2) • Seal off line and connections with sealing caps

12. 12. Detach charge air pipe (3) from camshaft housing cover • Detach camshaft vent hose (1) from charge air pipe – Release clamp • Unclip hose for wastegate unit of exhaust gas recirculation cooler bypass valve (2) • Unscrew bolt

13. 13. Detach vacuum hose (1) of wastegate unit for exhaust gas recirculation cooler • Unclip 3x • Set vacuum hose aside

14. 14. Detach engine management wiring trough (1) from camshaft housing cover • Unscrew 3 bolts (arrows)

15. 15. Disconnect engine management wiring harness plugs • Disconnect 14x wiring harness plugs – EGR valve – Air mass flow meter – Camshaft sensor – Compressor – 4x injector – 4x sheathed glow plugs – Air intake temperature – Coolant temperature sensor • Unclip 2x wiring harnesses

Note. Release with EN-48558 and pull off by hand

16. 16. Remove 4x high-pressure lines • Unscrew 8x union nut (1) • Seal off connections on pressure chamber with suitable sealing caps

17. 17. Remove camshaft housing cover (2) • Unscrew 10x bolt • Remove 4x injector seals (1) • Remove camshaft housing cover • Seal off connections on injector with EN-48559

18. 18. Remove 4x injector (1) • Remove 4x brackets (2) – Unscrew 4x bolts

19. 19. Detach coolant hose (1) from thermostat housing cover • Release clamp

20. 20. Remove exhaust gas recirculation valve (1) • Detach EGR cooler pipe (2) – Unscrew 2x bolts – Remove gasket • Unscrew 4x bolts – Remove gasket

21. 21. Detach charge air hose for throttle valve connection (1) • Release clamp

22. 22. Detach intake pipe rear bracket (2) from intake pipe (6) • Unscrew 2x bolts (1)
23. 23. Remove intake pipe together with throttle valve module • Disconnect wiring harness plug for throttle valve module – Unclip wiring harness • Remove intake pipe lower bracket (5) – Unscrew bolt (3) – Unscrew nut (4) • Unscrew 3 bolts (arrows) • Unclip vacuum hose • Remove gasket

24. 24. Detach brake servo vacuum line (2) from vacuum pump
25. 25. Detach vacuum hose (1) from vacuum pump

26. 26. Remove vacuum pump (2) • Unscrew 3x bolts (1)

27. 27. Remove toothed belt
28. 28. Turn crankshaft 60°
29. 29. Lower vehicle by its full height
30. 30. Remove camshaft sprocket • Remove TDC fixing bolt (1) – Unscrew bolt

Note. Counterhold it with KM-6347 (3) together with KM-956-1 (2)

31. 31. Remove camshaft bearing cap 5 (1) • Unscrew 2x nuts (3) • Unscrew bolt (2)

32. 32. Lock exhaust camshaft gear wheels • Lock balancer gear wheel, exhaust camshaft (3), with balancer camshaft gear wheel (1) with KM-6092-10 (2) so that it cannot twist

33. 33. Remove 2x camshafts • Release the camshaft bearing caps in the order specified, working in a spiral pattern in stages of 1/2 to 1 turn

Note. Note marking before dismantling camshaft bearing cap

Note. When replacing the exhaust camshaft, the balancer gear wheel (2) must be pre-tensioned with KM-6092 (1) and connected to the gear wheel of the exhaust camshaft (3) with fixing pin KM-6092-10 (4)

34. 34. Remove 16x cup tappets with KM-845 • Mark assignments

Install

35. 35. Install 16x cup tappets with KM-845 • Coat with engine oil

Note. Observe correct assignment

36. 36. Remove camshaft seal ring (1)

37. 37. Clean sealing surface • Camshaft housing, camshaft bearing caps

Important. When installing the camshafts, ensure that the mark (1) on the exhaust camshaft gear wheel is between the two marks (2) on the intake camshaft gear wheel and that the marks on the camshaft bearing cap (4) are in line with the two marks on the camshafts (3)

38. 38. Insert 2x camshafts • Insert camshaft in camshaft housing

Note. Coat bearing positions with engine oil

39. 39. Tighten 2x camshafts • Attach camshaft bearing caps 1 - 4 to camshaft housing • Attach camshaft bearing cap 5 – Remove KM-6092-10 from exhaust camshaft gear wheel • Tighten the camshaft bearing caps in the order specified (1 - 15) in stages of 1/2 to 1 turn – Tighten 10x nuts 22 Nm – Tighten 5x bolts 27 Nm

Note. Coat bearing positions with engine oil

Note. Arrows on bearing caps point towards engine timing side

40. 40. Insert camshaft seal ring • Drive in flush using KM-656 (1)

41. 41. Check valve clearances and adjust if necessary
42. 42. Install camshaft sprocket • Tighten bolt 111 Nm – Counterhold with KM-6347 in conjunction with KM-956-1 • Screw in TDC fixing bolt

Note. Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket

Important. Do not damage increment disc

43. 43. Raise vehicle by its full height
44. 44. Install toothed belt
45. 45. Install vacuum pump • Replace gasket • Tighten 3x bolt 24 Nm

Note. Pay attention to position of teeth

Note. Note guide sleeves

46. 46. Attach vacuum hose to vacuum pump

Important. Quick-release fitting must audibly engage

47. 47. Attach brake servo vacuum line to vacuum pump
48. 48. Install intake pipe together with throttle valve module • Replace gasket • Tighten 3x bolt 16 Nm • Connect wiring harness plug, throttle valve module – Attach wiring harness • Install intake pipe lower bracket – Tighten bolt – Tighten nut • Clip in vacuum hose
49. 49. Attach intake pipe bracket to intake pipe • Tighten 2x bolts
50. 50. Attach charge air hose for throttle valve connection • Tighten clamp 3.5 Nm
51. 51. Install EGR valve • Replace gasket • Tighten 4x bolts 24 Nm • Attach exhaust gas recirculation cooler pipe – Replace gasket – Tighten 2x bolts 29 Nm

Note. Attach coolant hose bracket

52. 52. Attach coolant hose to thermostat housing. • Fasten clamp
53. 53. Detach pressure chamber (1) • Unscrew 2x bolts (2) 1 - 1 1/2 turns

54. 54. Install 4x injector • Install 4x brackets – Align injectors with EN-48560 (1)

Note. Replace 4x injector seals

55. 55. Attach 4x high-pressure lines from pressure chamber to injector • Tighten 8x union nuts hand-tight
56. 56. Fasten 4x injectors • Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

57. 57. Fasten pressure chamber • Tighten 2x bolt 25 Nm
58. 58. Detach 4x high-pressure lines from pressure chamber to injector • Unscrew 8x union nuts • Seal off connections on pressure chamber with suitable sealing plugs • Seal off connections on injectors with EN-48559
59. 59. Clean sealing surface

Important. Oil return bore (2) may not be covered with adhesive sealing compound

60. 60. Apply sealing compound • Apply adhesive sealing compound to sealing surfaces (1) and (3)

Note. Select a suitable sealing compound from the replacement parts catalogue

61. 61. Install camshaft housing cover • Detach 4x EN-48559 from injector • Tighten 10x bolts 10 Nm • Install 4x injector seals
62. 62. Install 4x high-pressure lines • Detach 4x sealing caps from pressure chamber • Tighten 8x union nut 25 Nm

Note. Attach first to injector, then to pressure chamber

63. 63. Connect engine management wiring harness plugs • Connect 14x wiring harness plugs – EGR valve – Air mass flow meter – Camshaft sensor – Compressor – 4x injector – 4x sheathed glow plugs – Air intake temperature – Coolant temperature sensor • Clip in 2x wiring harnesses
64. 64. Attach engine management wiring trough to camshaft housing cover • Tighten 3x bolts
65. 65. Attach vacuum hose to wastegate unit for exhaust gas recirculation cooler • Route vacuum hose • Clip in 3x
66. 66. Attach charge air pipe to camshaft housing cover • Tighten bolt • Attach camshaft vent hose to charge air pipe – Fasten clamp • Clip in hose for wastegate unit of exhaust gas recirculation cooler bypass valve
67. 67. Attach fuel return line to injector • Detach sealing caps • Replace 4x seal rings • Fasten 4x retaining clamps
68. 68. Connect engine timing wiring harness (top) • Lay wiring harness • Attach positive cable to fuse carrier – Tighten nut • Connect and lock wiring harness plug • Attach wiring harness

Note. Pay attention to installation position

69. 69. Raise vehicle by half its height
70. 70. Attach wiring harness to engine control unit • Connect wiring harness plug to control unit and lock • Clip wiring harness into bracket • Clip 3x wiring harnesses to engine
71. 71. Lower vehicle by half its height
72. 72. Install battery holder • Tighten 3x bolts • Clip in wiring harness plug • Attach wiring harness – Clip 2x to battery support • Clip in bracket for coolant hose • Clip in control unit of pre-heating system
73. 73. Install battery • Install bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
74. 74. Connect battery • Attach ground cable to ground terminal – Tighten nut
75. 75. Install air intake pipe. • Tighten clamp 3.5 Nm

Important. Wear protective goggles

76. 76. Carry out leak test on high pressure system • Carry out actuator test (fuel leak) • Visual inspection of high pressure system for fuel leak

Note. Engine must be at operating temperature

77. 77. Program volatile memories
78. 78. Install engine cover
79. 79. Install air cleaner housing