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Replace all valve stem seals (cylinder head installed) > < Engine, engine attaching parts Camshaft sprockets, X 20 XEV

Astra G

All Valve Stem Seals, Replace (Cylinder Head Installed)

  Remove

1.   Remove all the hydraulic valve lifters
•   See operation "Hydraulic Valve Lifter, Remove and Install"
2.   Remove spark plugs
•   4 off
•   using KM-194-E
3.   Raise vehicle
4.   Apply aid marks.
•   On toothed belt drive belt.
Note:   180° offset to the TDC cylinder 1 mark (arrow).
Object Number: 2402855 Size: DEFAULT


5.   Turn crankshaft to ignition TDC marking, cylinder no. 1
6.   Block crankshaft.
•   using KM-911
7.   Lower vehicle
8.   Complete valve spring lever automatic system.
•   Adjust supports.
Note:   Set support head (1) centrally to the support feet (2) and tighten.
•   Complete lever arm.
– With joint, removal head
•   Complete assembly head
– For X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE and Z 16 YNG use MKM-6086-100-1 and MKM-6086-100-10
– For X 18 XE, Z 18 XE and Z 18 XEL use MKM-6086-200-1 and MKM-6086-200-10
– Insert thrust piece (3)
Object Number: 2411369 Size: DEFAULT


9.   Attact valve spring lever automatic system
•   Attach supports
– At camshaft bearing cover positions 1 and 4
– Insert assembly shaft in supports
Note:   Align assembly shaft centrally via the spark plug bore
– Tighten 4 bolts
•   Attach lever arm (1)
Note:   Removal head (2) must point towards intake side
•   Secure installation shaft
– Tighten 2 bolts
10.   Fit compressed air adapter (3)
•   Screw into spark plug thread cylinder 1
•   Apply compressed air to cylinder 1
Object Number: 2411370 Size: DEFAULT


11.   Remove intake valve springs on cylinder no. 1
•   2 off
•   Carefully push valve springs downwards
– With lever arm
Note:   Removal head must stand vertically above valve stem
Important:   Observe correct assignment
•   Remove valve cotters, plates and springs
Note:   Do not use magnetic tools
12.   Replace valve stem seals
•   2 off
•   Remove with KM-840 (1)
•   Place new valve shaft seal onto valve shaft
•   Drive to stop using KM-835-A (2)
Object Number: 2411371 Size: DEFAULT


13.   Install intake valve springs, cylinder no. 1
•   2 off
•   Insert valve springs, plates
•   Insert valve cotters (1) in assembly head
– Push clamping sleeve (2) towards the lever arm holder
Important:   Insert valve cotters with tapered end towards valve
– Push clamping sleeve towards the valve
•   Attach assembly head to lever arm
•   Carefully push valve springs downwards
Important:   Assembly head must stand vertically above valve stem
– With lever arm
Note:   Valve cotters must engage audibly
Object Number: 2418512 Size: DEFAULT


Important:   Do not make a 2nd attempt without checking that both valve cotters are in the assembly head. Check valve cotter seat. Ensure application of compressed air.
14.   Check installation position
15.   Convert lever arm
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
Note:   Removal head must point towards exhaust side
16.   Remove exhaust valve springs from cylinder no. 1
•   2 off
•   Carefully push valve springs downwards
– With lever arm
Note:   Dismantling head (1) must be vertical position above valve stem
Important:   Observe correct assignment
•   Remove valve cotters, plates and springs
Note:   Do not use magnetic tools
Object Number: 2411372 Size: DEFAULT


17.   Replace valve stem seals
•   2 off
•   Remove with KM-840
•   Place new valve shaft seal onto valve shaft
•   Drive to stop using KM-835-A
18.   Install exhaust valve springs on cylinder no. 1
•   2 off
•   Insert valve springs, plates
•   Insert valve cotters in assembly head
– Push clamping sleeve towards the lever arm holder
Important:   Insert valve cotters with tapered end towards valve
– Push clamping sleeve towards the valve
•   Attach assembly head to lever arm
•   Carefully push valve springs downwards
Important:   Assembly head must stand vertically above valve stem
– With lever arm
Note:   Valve cotters must engage audibly
Important:   Do not make a 2nd attempt without checking that both valve cotters are in the assembly head. Check valve cotter seat. Ensure application of compressed air.
19.   Check installation position
20.   Convert compressed air adapter
•   Interrupt compressed air feed
•   Unscrew from spark plug thread cylinder 1
•   Screw into spark plug thread cylinder 4
•   Apply compressed air to cylinder 4
21.   Convert lever arm
•   Release assembly shaft
– Slacken 2 bolts
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
•   Secure installation shaft
– Tighten 2 bolts
Object Number: 2411373 Size: DEFAULT


22.   Replace valve stem seals, cylinder no. 4
23.   Interrupt compressed air feed
24.   Raise vehicle
25.   Remove KM-911
26.   Set cylinder 3 to TDC of combustion stroke
•   Turn crankshaft evenly (180°)
Note:   Alignment marking of toothed belt drive wheel must align with marking at the rear of the toothed belt cover
27.   Block crankshaft.
•   Insert KM-911
28.   Lower vehicle
29.   Transfer valve spring lever automatic system
•   Transfer supports
– At camshaft bearing cover positions 1 and 5
– Insert assembly shaft in supports
Note:   Align assembly shaft centrally via the spark plug bore
– Tighten 4 bolts
•   Install lever arm
Note:   Removal head must point towards intake side
•   Secure installation shaft
– Tighten 2 bolts
30.   Transfer compressed air adapter
•   From spark plug thread cylinder 4
•   Screw into spark plug thread cylinder no. 2
•   Apply compressed air to cylinder 2
Object Number: 2411374 Size: DEFAULT


31.   Replace valve stem seals, cylinder no. 2
•   4 off
32.   Convert compressed air adapter
•   Interrupt compressed air feed
•   Unscrew from spark plug thread cylinder 2
•   Screw into spark plug thread cylinder 3
•   Apply compressed air to cylinder 3
33.   Replace valve stem seals, cylinder no. 3
•   4 off
34.   Interrupt compressed air feed
35.   Detach valve spring lever automatic system
36.   Remove compressed air adapter
37.   Visually check components
•   Camshafts, camshaft bearing cover, hydraulic tappets, cylinder head, ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulley, toothed belt drive, spark plugs

  Install

38.   Install spark plugs
•   Tighten with KM-194-E
– Tightening torque 25 Nm
39.   Raise vehicle
40.   Remove KM-911
41.   Position crankshaft
Note:   Set crankshaft to 60° before TDC combustion stroke on cylinder 1 (I)
Object Number: 2398324 Size: DEFAULT


42.   Lower vehicle
43.   Install all the hydraulic valve lifters
•   See operation "Hydraulic Valve Lifter, Remove and Install"
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Replace all valve stem seals (cylinder head installed) > < Engine, engine attaching parts Camshaft sprockets, X 20 XEV