How to Replace the Cup Tappets Opel Meriva A

Important: When working on the fuel system, it is essential that a high degree of cleanliness is maintained, as even the smallest particles of dirt can cause engine or fuel system malfunctions. Any fuel system connections which have been opened must be closed off with suitable sealing plugs available from the Opel Parts Catalogue. Sealing plugs are intended for single use only.

Remove

1. 1. Remove air cleaner housing
2. 2. Remove air intake hose (1) • Undo 2x clamps (arrows) • Unscrew 2x bolts (2)

3. 3. Remove battery support.
4. 4. Raise vehicle by half its height
5. 5. Release engine control unit wiring harness • Release and disconnect 2x wiring harness plugs (1) • Unclip 5x wiring harnesses (arrows)

6. 6. Lower vehicle by half its height
7. 7. Remove coolant compensation tank • Unscrew bolt (2) • Undo spreader rivet (1) • Unclip coolant hose from exhaust gas recirculation valve • Unclip compensation tank • Detach 3x coolant hoses from compensation tank – Release retaining clamp – Release 2x clamp

8. 8. Detach vacuum hose of wastegate unit for bypass valve (1) • Unclip 4x • Place hose to one side

9. 9. Place collecting basin underneath
10. 10. Detach fuel return line (1) from injector • 4x from injector – Release retaining clamps (2) • Close off line and connections with cover caps

11. 11. Detach engine management wiring harness (1) • Detach charge air hose from throttle valve module – Release clamp • Remove wiring trough – Unscrew 3x bolts (arrows) • Disconnect 13x wiring harness plugs – 4x injectors – 4x sheathed glow plugs – Intake air temperature sensor – EGR valve – Throttle valve connection – Coolant temperature sensor – Accumulator • Unclip 4x wiring harnesses • Pull engine control unit wiring harness upwards • Place engine management wiring harness to one side

Note. Release with EN-48558 and pull off manually

12. 12. Detach charge air pipe (3) from camshaft housing cover • Detach camshaft vent hose (1) from charge air pipe – Detach heat insulation – Release clamp • Unclip wastegate unit for bypass valve of exhaust gas recirculation cooler (2) • Unscrew bolt • Pull charge air pipe forwards and secure to crossmember with cable tie

13. 13. Remove 4x high pressure lines between accumulator and injectors • Unscrew 8x union nuts (1) • Close off the accumulator connections with suitable sealing plugs • Close off the injector connections with EN-48559

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

15. 15. Remove 4x injectors (1) • Remove 4x holders (2) – Unscrew 4x bolt

16. 16. Remove exhaust gas recirculation valve (1) • Detach exhaust gas recirculation cooler pipe (2) – Unscrew 2x bolt – Remove seal • Unscrew 4x bolt – Remove seal

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

18. 18. Detach rear intake pipe bracket (2) from intake pipe (6) • Unscrew 2x bolt (1)
19. 19. Remove intake pipe with throttle valve module • Detach charge air hose from throttle valve module – Release quick-release fitting • Disconnect throttle valve module wiring harness plug – Unclip wiring harness • Remove bracket under intake pipe (5) – Unscrew bolt (3) – Unscrew nut (2) • Unscrew 3x bolts (arrows) • Unclip vacuum hose • Remove seal

20. 20. Remove rear intake pipe bracket • Unscrew 2x bolt
21. 21. Detach brake servo vacuum line (2) from vacuum pump
22. 22. Detach vacuum hose (1) from vacuum pump

23. 23. Remove vacuum pump (2) • Unscrew 3x bolt (1)

24. 24. Remove toothed belt
25. 25. Lower vehicle all the way
26. 26. Turn crankshaft until cam pairs (1) and (2) are pointing upwards

27. 27. Check valve play with feeler gauge (1) • Test values: see technical data

Note. The valve play is checked on a cold engine – room temperature.

28. 28. Turn crankshaft • 180 °in direction of engine rotation – Check valve play at cam pairs (6) and (2) • 180 °in direction of engine rotation – Check valve play at cam pairs (5) and (3) • 180 °in direction of engine rotation – Check valve play at cam pairs (4) and (1) • Test values: see technical data

29. 29. Remove camshaft sprocket • Remove TDC locking bolt (1) – Unscrew bolt

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

30. 30. Detach camshaft bearing cap 5 (1) • Unscrew 2x nut (3) • Unscrew bolt (2)

31. 31. Lock gears of exhaust camshaft • Using KM-6092-10 (2) lock exhaust camshaft differential gear (3) with exhaust camshaft gear (1) to prevent twisting

32. 32. Detach 2x camshafts • Slacken the camshaft bearing caps in the specified sequence, working in a spiral pattern. Slacken them in stages of 1/2 to 1 turn

Note. Note marking before dismantling camshaft bearing cap

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

33. 33. Remove camshaft seal ring (1)

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

Install

35. 35. Determine size of the cup tappets Example of how to determine the size of a cup tappet: Dimension of the cup tappet installed 3.66 mm (code 66) Measurement between cam and cup tappets + 0.44 mm = 4.10 mm Required valve play for intake side - 0.40 mm Nominal dimension of the new cup tappet 3.70 mm (code 70) • A cup tappet of this dimension or of the nearest dimension to it is now used

Note. The code (arrow) is located on the inside of the cup tappet

Note. See technical data for information on assignment of codes

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

Note. Observe correct assignment

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

Important. When installing the camshafts ensure that the mark (1) of the exhaust camshaft gear is between the two marks (2) on the intake camshaft gear 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

Note. Coat bearing points 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 • Tighten the camshaft bearing caps in the specified sequence (1-15), working in stages of 1/2 to 1 turn – Tighten 10x nuts 22 Nm – 5x bolts 27 Nm

Note. Coat bearing points with engine oil

Note. Arrows on bearing cap point to engine timing side.

40. 40. Check the valve play again, adjust if necessary
41. 41. Attach camshaft seal ring • Drive in flush using KM-656 (1)

42. 42. Install camshaft sprocket • Tighten bolt 111 Nm – Counterhold with KM-6347 in combination with KM-956-1 • Screw in TDC locking bolt

Note. Camshaft journal (2) must engage in hole (1) of camshaft sprocket

Important. Do not damage the increment disc

43. 43. Raise vehicle all the way
44. 44. Install toothed belt
45. 45. Install vacuum pump • Replace seal • Tighten 3x bolts 24 Nm

Note. Note position of teeth

Note. Note guide sleeves

46. 46. Attach vacuum hose to vacuum pump

Important. Quick-release fastening must audibly engage

47. 47. Connect brake servo vacuum line to vacuum pump
48. 48. Install rear intake pipe bracket • Tighten 2x bolts 24 Nm
49. 49. Install intake pipe with throttle valve module • Replace seal • Tighten 3x bolts 16 Nm • Connect throttle body wiring harness plug – Attach wiring harness • Install bracket under intake pipe – Tighten bolt – Tighten nut • Clip in vacuum hose • Attach charge air hose to throttle valve module – Connect quick release fitting
50. 50. Attach intake pipe bracket to intake pipe • Tighten 2 bolts
51. 51. Attach coolant hose to thermostat housing. • Fasten clamp
52. 52. Install exhaust gas recirculation valve • Replace seal • Tighten 4x bolts 24 Nm • Attach exhaust gas recirculation cooler pipe – Replace seal – Tighten 2x bolts 29 Nm

Note. Attach coolant hose bracket

53. 53. Install 4x injectors • Fit 4x holders – Align injectors with EN-48560 – Tighten 4x bolts in three stages – 1. Tighten bolt 40 Nm – 2. Undo bolt – 3. Tighten bolt 32 Nm

Note. Replace 4 gaskets of the injectors

54. 54. Clean sealing surface

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

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

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

56. 56. Install camshaft housing cover • Tighten 10x bolts 10 Nm • Install 4x injector seals
57. 57. Install 4x high pressure lines • Detach 8x cover caps • 8 union nuts with 25 Nm
58. 58. Attach charge air pipe to camshaft housing cover • Cut cable ties • Tighten bolt 5 Nm • Attach camshaft vent hose to charge air pipe – Fasten clamp – Attach heat insulation
59. 59. Attach engine management wiring harness • Route wiring harness • Route engine control unit wiring harness downwards – Clip in 3x • Attach wiring trough – Tighten 3 bolts • Connect 13x wiring harness plugs – 4x injectors – 4x sheathed glow plugs – Intake air temperature sensor – EGR valve – Throttle valve connection – Coolant temperature sensor – Accumulator • Clip in 4x wiring harnesses • Attach charge air hose to throttle valve module – Tighten clamp
60. 60. Attach fuel return line to injector • Replace 4x seal rings • Fasten 4x retaining clamps
61. 61. Attach vacuum hose of wastegate unit for bypass valve • Lay hose • Clip in 4x
62. 62. Install coolant expansion tank • Attach 3x coolant hoses to compensation tank – Fasten retaining clamp – Attach 2x clamps • Tighten bolt • Fasten spreader rivet • Clip coolant hose to exhaust gas recirculation valve
63. 63. Raise vehicle by half its height
64. 64. Attach engine control unit wiring harness • Connect and lock 2x wiring harness plugs • Clip in 2x wiring harnesses
65. 65. Lower vehicle by half its height
66. 66. Install battery carrier

Important. Wear protective goggles

67. 67. Carry out a leak test on the 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

68. 68. Install air intake hose. • Attach 2x clamps • Tighten 2 bolts
69. 69. Install air cleaner housing