Vauxhall Workshop Service and Repair Manuals

Cup Tappets, Replace

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

4.   Remove air intake pipe (1) together with air mass flow meter •   Release clamp •   Disconnect wiring harness plug of air-flow meter

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

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

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

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

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.   Remove 2x camshafts Note:   Note marking before dismantling camshaft bearing cap •   Release the camshaft bearing caps in the order specified, working in a spiral pattern in stages of 1/2 to 1 turn 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)

  Install

21.   Remove camshaft seal ring (1)

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.   Insert 2x camshafts •   Insert camshaft in camshaft housing Note:   Coat bearing positions with engine oil

24.   Tighten 2x camshafts Note:   Coat bearing positions with engine oil •   Attach camshaft bearing caps 1 - 4 to camshaft housing Note:   Arrows on bearing caps point towards engine timing side •   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

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

26.	Check valve clearances and adjust if necessary

27.   Install camshaft sprocket Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket •   Tighten bolt 111 Nm – Counterhold it with KM-6347 together with KM-956-1 Important:   Do not damage increment disc •   Screw in TDC fixing bolt

31.   Install 4x injector Note:   Replace 4x injector seals •   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

Important:   Oil return bore (2) may not be covered with adhesive sealing compound 33.   Apply sealing compound Note:   Select a suitable sealing compound from the replacement parts catalogue •   Apply adhesive sealing compound to sealing surfaces (1) and (3)