How to Replace the Cup Tappets Opel Corsa D

Important: When working on the fuel system maintaining cleanliness is essential, otherwise the smallest particles of dirt may result in engine operating faults or faults in the fuel system. 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. Open bonnet
2. 2. Disconnect battery • Detach negative clamp from earth terminal – Undo nut
3. 3. Remove engine cover
4. 4. Remove air intake pipe (1) together with air mass flow meter • Release clamp • Disconnect wiring harness plug of air-flow meter

5. 5. Place collecting basin underneath.
6. 6. Detach fuel return line (1) from injector • 4x from injector – Release retaining clamps (2) • Seal off line and connections with sealing caps

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

8. 8. Remove 4x high-pressure lines • Unscrew 8x lock nut (1) • Seal off connections on pressure chamber with suitable sealing caps • Seal off connections on injector with EN-48559

9. 9. Remove camshaft housing cover (2) • Unscrew 10x bolt • Remove 4x injector seals (1)

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

11. 11. Remove vacuum pump
12. 12. Remove toothed belt
13. 13. Turn crankshaft 60°
14. 14. Lower vehicle by its full height
15. 15. Remove camshaft sprocket • Remove TDC fixing bolt (1) – Unscrew bolt

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

16. 16. Remove camshaft bearing cap 5 (1) • Unscrew 2x nut (3) • Unscrew bolt (2)

17. 17. 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

18. 18. 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)

19. 19. Remove 16x cup tappets with KM-845 • Mark which is which

Install

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

Note. Observe correct assignment

21. 21. Remove camshaft seal ring (1)

22. 22. 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)

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

Note. Coat bearing positions with engine oil

24. 24. 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 – 10x nuts 22 Nm – 5x bolts 27 Nm

Note. Coat bearing positions with engine oil

Note. Arrows on bearing caps point towards engine timing side

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

26. 26. Check valve clearances and adjust if necessary
27. 27. Install camshaft sprocket • Tighten bolt 111 Nm – Counterhold it with KM-6347 together 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

28. 28. Raise vehicle by its full height
29. 29. Install toothed belt
30. 30. Install vacuum pump
31. 31. Install 4x injector • Install 4x brackets – Align injectors with EN-48560 (1) – Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

Note. Replace 4x injector seals

32. 32. Clean sealing surface

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

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

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

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

Note. Attach first to injector, then to pressure chamber

36. 36. Fit charge air pipe • Tighten clamp 3.5 Nm • Tighten bolt • Attach engine vent hose to camshaft housing cover – Fasten clamp – Fit heat insulation
37. 37. Attach fuel return line to injector • Replace 4x seal rings • Fasten 4x retaining clamps
38. 38. Install air intake pipe together with air mass flow meter • Tighten clamp • Connect mass air flow meter wiring harness plug
39. 39. Install engine cover
40. 40. Connect battery • Attach earth clamp to earth terminal – Tighten nut
41. 41. Program volatile memories
42. 42. Close bonnet