vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace all valve stem seals (cylinder head installed) > < Replace all valve stem seals (cylinder head installed)

Astra H

Check and adjust valve play

  Remove

1.   Open bonnet
2.   Disconnect battery
3.  
1. Remove air cleaner housing - Z16XEP LUREF_1.gif
2. Remove air cleaner housing - Z16XE1 LUREF_1.gif

4.   Remove DIS-ignition module
•   Remove cover of DIS-ignition module in the direction of the arrow
Note:   Note arrow on cover
•   Unscrew 2x bolts
•   Remove from spark plugs using KM-6009 (1)
Object Number: 2412812 Size: DEFAULT


5.   Detach front toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
•   Release upper catch (3)
•   Pull front toothed belt cover (top) upwards by cast projection (arrow), applying slight tension
Object Number: 2412882 Size: DEFAULT


6.   Detach cylinder head cover (1)
•   Unclip wiring trough
•   Unlatch and remove engine vent pipe
•   Slacken 3x bolt (3) pull upwards and fix in this position with adhesive tape
•   Slacken 6x bolts (2)
Note:   Care should be taken that the area of the front camshaft bearing caps (arrows) is clean and free from remains of sealant
Object Number: 2412908 Size: DEFAULT


7.   Set engine to TDC
•   Move torsional vibration damper in direction of engine rotation to the "cylinder 1 TDC of combustion stroke position" (1)
Object Number: 2412844 Size: DEFAULT


8.   The cams at the intake side of cylinder 2 (1) and the exhaust side of cylinder 3 (2) point upwards and slightly towards the inside at the same angle
Object Number: 2412956 Size: DEFAULT


9.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm)
– Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm)
10.   Check 4 valves
•   Check valve lash with KM-6361 (1)
– Note down result
Object Number: 2412919 Size: DEFAULT


11.   Turn crankshaft 180° in the direction of rotation of the engine
•   Corresponds to 90° on the camshaft
– Use the markings on the camshaft sprockets for orientation purposes
•   Cams on the intake side of cylinder 1 (1) and the exhaust side of cylinder 4 (2) point upwards and slightly towards the inside at the same angle
Object Number: 2412957 Size: DEFAULT


12.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm)
– Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm)
13.   Check 4 valves
•   Check valve lash with KM-6361 (1)
– Note down result
Object Number: 2412919 Size: DEFAULT


14.   Turn crankshaft 180° in the direction of rotation of the engine
•   Corresponds to 90° on the camshaft
– Use the markings on the camshaft sprockets for orientation purposes
•   Cams on the intake side of cylinder 3 (1) and the exhaust side of cylinder 2 (2) point upwards and slightly towards the inside at the same angle
Object Number: 2412958 Size: DEFAULT


15.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm)
– Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm)
16.   Check 4 valves
•   Check valve lash with KM-6361 (1)
– Note down result
Object Number: 2412919 Size: DEFAULT


17.   Turn crankshaft 180° in the direction of rotation of the engine
•   Corresponds to 90° on the camshaft
– Use the markings on the camshaft sprockets for orientation purposes
•   The cams on the intake side of cylinder 4 (1) and the exhaust side of cylinder 1 (2) point upwards and slightly towards the inside at the same angle
Object Number: 2412959 Size: DEFAULT


18.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm)
– Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm)
19.   Check 4 valves
•   Check valve lash with KM-6361 (1)
– Note down result
Object Number: 2412919 Size: DEFAULT


20.   Raise lifting platform
21.   Remove engine splash guard (2).
•   Unscrew 4x bolts (1)
•   Remove 2x body-bound rivets (3)
Object Number: 3446244 Size: DEFAULT


22.   Set engine to 60° before TDC
•   Set crankshaft in direction of engine rotation to 60° (measurement l) before TDC
Object Number: 2412867 Size: DEFAULT


23.   Lower lifting platform
24.   Remove toothed belt
•   Mark direction of rotation
•   Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allen key (1). Fix using KM-6333 (3)
– Remove toothed belt
Object Number: 2412854 Size: DEFAULT


25.   Detach exhaust camshaft sprocket
•   Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Slacken 2x bolt (3) of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
•   Release bolt of camshaft sprocket (4)
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Undo 2x bolts
•   Unscrew bolt, camshaft sprocket
– Remove camshaft sprocket
Object Number: 2412855 Size: DEFAULT


26.   Detach intake camshaft sprocket
•   Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken 2x bolt of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
•   Slacken bolt of camshaft sprocket
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Undo 2x bolts
•   Unscrew bolt, camshaft sprocket
– Remove camshaft sprocket
27.   Slacken camshaft bearing cap, exhaust camshaft
•   Slacken camshaft bearing caps working in spiral from outside to inside in steps of 1/2 up to 1 turn
Object Number: 2412913 Size: DEFAULT


28.   Remove exhaust camshaft
Note:   Note marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes)
•   Remove the camshaft bearing cover from the cylinder head and take out the camshaft
Object Number: 2412962 Size: DEFAULT


29.   Slacken camshaft bearing cap, intake camshaft
•   Slacken camshaft bearing caps working in spiral from outside to inside in steps of 1/2 up to 1 turn
Object Number: 2412913 Size: DEFAULT


30.   Remove intake camshaft
Note:   Note marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes)
•   Remove the camshaft bearing cover from the cylinder head and take out the camshaft
Object Number: 2412962 Size: DEFAULT


31.   Remove cup tappet with KM-845 (1)
Object Number: 2412921 Size: DEFAULT


  Install

32.   Determine cup tappet size

Example of determining the size of a cup tappet, intake side:

      

Dimension of fitted cup tappet

  

3.20 mm

(Identification no. 20)

Measurement between cams and cup tappets

+

0.31 mm

  
 

=

3.51 mm

  

Required value, valve lash, intake side

-

0.25 mm

  

Nominal dimension of the new cup tappet

  

3.265 mm

(Identification number 27x
Note:   The identification number (arrow) is on the inside of the cup tappet
•   Now use a cup tappet with this dimension or one that is nearest to it
Object Number: 2412960 Size: DEFAULT


33.   Insert cup tappet with KM-845
•   Lightly coat sliding surfaces with oil
34.   Install intake camshaft
•   Coat with MoS 2 lubricating paste
•   Insert camshaft
Note:   Note the identification marking on the camshaft bearing cover
•   Apply surface sealant to sealing surface of guide bearing (arrows)
•   Install camshaft bearing cover
– Tighten camshaft bearing caps in a spiral from the inside outward 8 Nm
Object Number: 2398329 Size: DEFAULT


35.   Install exhaust camshaft
•   Coat with MoS 2 lubricating paste
•   Insert camshaft
Note:   Note the identification marking on the camshaft bearing cover
•   Apply surface sealant to sealing surface of guide bearing (arrows)
•   Install camshaft bearing cover
– Tighten camshaft bearing caps in a spiral from the inside outward 8 Nm
Object Number: 2398329 Size: DEFAULT


36.   Install seal ring, exhaust camshaft
•   Push seal ring into camshaft bearing cover with KM-422 (1)
– Use camshaft sprocket bolt (2) and washer (3)
Object Number: 2412914 Size: DEFAULT


37.   Install seal ring, intake camshaft
•   Push seal ring into camshaft bearing cover with KM-422 (1)
– Use camshaft sprocket bolt (2) and washer (3)
Object Number: 2412914 Size: DEFAULT


38.   Replace gasket, cylinder head cover
•   Insert new gasket (1) in cylinder head cover
Object Number: 2412955 Size: DEFAULT


39.   Remove spark plug, cylinder 1 with KM-6363
40.   Install KM-6354 (1) in spark plug thread, cylinder 1
Object Number: 2412922 Size: DEFAULT


Important:   When assembling the cylinder head cover, care must be taken that the gasket of the cylinder head cover does not become detached. An incorrectly fitted gasket in the cylinder head cover can cause serious damage to the engine
41.   Place cylinder head cover in position
•   Lift cylinder head cover via KM-6354
•   Position cylinder head cover at the rear (i)
•   Press cylinder head cover carefully downwards at the back (II)
•   Unscrew KM-6354 (1)
Object Number: 2412923 Size: DEFAULT


42.   Attach cylinder head cover
•   Remove adhesive tape from 3 bolts
•   Tighten 12x bolt 8 Nm
•   Attach engine vent pipe and latch
•   Clip in wiring trough
43.   Install spark plug cylinder 1 with KM-6363 25 Nm
44.   Remove DIS-ignition module
•   Tighten 2x bolt 8 Nm
•   Attach DIS ignition module cover
45.   Attach KM-6347 to exhaust camshaft sprocket
•   Position camshaft sprocket - note marking
•   Fit camshaft sprocket bolt (4)
– Do not tighten
– Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Slacken 2x bolt (3) of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
Object Number: 2412855 Size: DEFAULT


46.   Tighten outlet camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
47.   Attach KM-6347 to intake camshaft sprocket
•   Position camshaft sprocket - note marking
•   Screw in bolt, camshaft sprocket
– Do not tighten
– Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken 2x bolt of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
48.   Tighten intake camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
49.   Lock camshaft sprockets in position with KM-6340
•   Position camshaft sprockets in such a way that the markings (3) are opposite each other
•   Attach KM-6340-Left (1) to intake camshaft sprocket
•   Insert KM-6340-Right (2)
Object Number: 2412847 Size: DEFAULT


50.   Set engine to TDC
•   Move torsional vibration damper in direction of engine rotation to the "cylinder 1 TDC of combustion stroke position" (1)
Object Number: 2412844 Size: DEFAULT


51.   Install toothed belt
•   Position toothed belt
– Place toothed belt on exhaust camshaft sprocket
– Place toothed belt on intake camshaft sprocket
– Apply tension to the toothed belt tension roller and remove KM-6333
52.   Remove KM-6340
53.   Turn crankshaft through 720°
•   2 revolutions in direction of engine rotation
•   Place toothed belt drive gear on the marking, cylinder 1 TDC of combustion stroke (1)
Object Number: 2412844 Size: DEFAULT


54.   Lock camshaft sprockets in position with KM-6340
•   Insert KM-6340-Left (1)
•   Insert KM-6340-Right (2)
Note:   Markings (3) on camshaft sprockets must align - otherwise dismantle toothed belt and place in position again
Object Number: 2412847 Size: DEFAULT


55.   Remove KM-6340
Important:   Ensure that it is latched correctly
56.   Attach front toothed belt cover (top)
•   Tighten 2x bolt 6 Nm
57.  
1. Install air cleaner housing - Z16XEP LUREF_1.gif
2. Install air cleaner housing - Z16XE1 LUREF_1.gif

58.   Close bonnet

Replace all valve stem seals (cylinder head installed) > < Replace all valve stem seals (cylinder head installed)