Replace Cup Tappet Opel Corsa D

Important: Cleanliness is absolutely essential when working on the fuel system because even the smallest dirt particles can lead to disruption to engine operation or the fuel system. Open fuel systems must be sealed with appropriate sealing plugs from the Opel parts catalogue. Sealing plugs are only designed to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach negative clamp from ground terminal – Slacken nut
3. 3. Remove engine cover
4. 4. Remove air induction pipe (1) with air-flow sensor • Release clamp • Disconnect wiring harness plug of air-flow meter

5. 5. Remove waste gate case bypass valve vacuum hose • Unclip 4x • Set hose to one side
6. 6. Place collecting basin underneath.
7. 7. Detach fuel return line (1) from injector • From injector in 4 places – Loosen retaining clamps (2) • Close line and connections using closure caps

8. 8. Remove engine management wiring harness (1) • Detach charge air hose from throttle module – Disconnect quick-release coupling • Detach wiring trough – Unscrew 3 bolts • Disconnect 13 wiring harness plugs – 4 injectors – 4 glow plugs – Air intake temperature sensor – EGR valve – Throttle body – Coolant temperature sensor – Accumulator • Remove pre-heater system control unit wiring harness – Disconnect wiring harness connector. – Unclip wiring harness • Unclip wiring harness in 4 places

Note. Release EN-48558 and remove by hand

9. 9. Remove charge air pipe (3) • Remove camshaft vent hose (1) from charge-air tube – Remove thermal insulation – Release clamp • Unclip waste gate case bypass valve radiator exhaust gas return hose (2) • Unscrew bolt • Release clamp

10. 10. Remove 4 high-pressure lines • Unscrew 8 union nuts (1) • Close connections from accumulator using suitable closure caps • Close connections of injector using EN-48559

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

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

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

14. 14. Remove rear intake tube bracket (2) from induction pipe (6) • Unscrew 2x bolts (1)
15. 15. Remove induction pipe with throttle module • Disconnect wiring harness plug of throttle module – Unclip wiring harness • Remove bracket beneath induction pipe (5) – Unscrew bolt (3) – Unscrew nut (2) • Unscrew 3 bolts (arrows) • Unclip vacuum hose • Remove seal

16. 16. Remove rear induction pipe bracket • Unscrew 2x bolts
17. 17. Remove brake power assist unit vacuum line (2) from vacuum pump
18. 18. Remove vacuum hose from vacuum pump

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

20. 20. Remove toothed belt
21. 21. Rotate crankshaft by 60°
22. 22. Lower vehicle by its full height
23. 23. Remove camshaft sprocket • Remove TDC fixing bolt (1) – Unscrew bolt

Note. Counterhold with KM-6347 (3) in conjunction with KM-956-1 (2)

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

25. 25. 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

26. 26. Remove 2x camshafts • Release the camshaft bearing cap in the order specified in a spiral 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)

27. 27. Remove 16 cup tappets using KM-845 • Identify the assignment

Install

28. 28. Install 16 cup tappets using KM-845 • Coat with engine oil

Note. Observe allocation.

29. 29. Remove camshaft seal ring (1)

30. 30. Clean sealing surface • Camshaft housing, camshaft bearing cap

Important. When installing the camshafts, ensure that the marking (1) of the exhaust camshaft gear wheel is between the two markings (2) of the intake camshaft gear wheel and the markings of the camshaft bearing (4) align with the two markings of the camshafts (3)

31. 31. Insert 2 camshafts • Insert camshaft into camshaft housing

Note. Coat bearing positions with engine oil

32. 32. Tighten 2x camshaft • Attach camshaft bearing cap 1 - 4 to camshaft housing • Attach camshaft bearing cap 5 – Remove KM-6092-10 from exhaust camshaft gear wheel • Tighten camshaft bearing cap in specified tightening sequence (1 -- 15) in steps of 1/2 to 1 turn – 10 nuts 22 Nm – 5 bolts 27 Nm

Note. Coat bearing positions with engine oil

Note. Arrows on bearing cap point toward engine timing side

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

34. 34. Check and adjust valve play if necessary
35. 35. 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 disk

36. 36. Raise vehicle by its full height
37. 37. Install toothed belt
38. 38. Install vacuum pump • Replace seal • Tighten 3x bolt 24 Nm

Note. Observe the gearing position

Note. Note guide sleeves

39. 39. Attach vacuum hose to vacuum pump

Important. Quick-release coupling must audibly engage

40. 40. Attach brake power assist unit vacuum line to vacuum pump
41. 41. Install rear induction pipe bracket • Tighten 2x bolt 24 Nm
42. 42. Install induction pipe with throttle module • Replace seal • Tighten 3x bolt 16 Nm • Connect throttle module wiring harness plug – Attach wiring harness • Install bracket beneath induction pipe – Tighten bolt – Tighten nut • Clip in vacuum hose
43. 43. Attach induction pipe bracket to induction pipe • Tighten 2x bolts
44. 44. Attach coolant hose to thermostat housing. • Fasten clamp
45. 45. Install 4x injector • Install 4 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

46. 46. Clean sealing surface

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

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

Note. Select suitable sealing compound from the spare parts catalogue

48. 48. Install camshaft housing cover • Tighten 10 bolts 10 Nm • Install 4 injector seals
49. 49. Install 4 high-pressure lines • Remove 4 closure caps from accumulator • Detach 4 EN-48559 from injector • Tighten 8x union nut 25 Nm

Note. Attach first to injector, then to accumulator

50. 50. Install charge air pipe • Tighten clamp 3.5 Nm • Tighten bolt • Attach camshaft vent hose to charge-air tube – Fasten clamp – Attach thermal insulation
51. 51. Attach engine management wiring harness • Route wiring harness • Attach pre-heater system control unit wiring harness – Fix wiring harness plug – Attach wiring harness • Attach wiring trough – Tighten 3x bolts • Connect 13 wiring harness plugs – 4 injectors – 4 glow plugs – Air intake temperature sensor – EGR valve – Throttle body – Coolant temperature sensor – Accumulator • Clip wiring harness in 4 places • Attach charge air hose to throttle module – Quick-release coupling must audibly engage
52. 52. Attach fuel return line to injector • Replace 4x seal ring • Fasten 4 retaining clamps
53. 53. Attach waste gate case bypass valve vacuum hose • Route hose • Clip in 4x
54. 54. Install air induction pipe with air-flow sensor • Tighten clamp • Connect mass air flow meter wiring harness plug
55. 55. Install engine cover
56. 56. Connect battery • Attach negative clamp to ground terminal – Tighten nut
57. 57. Program volatile memories
58. 58. Close bonnet