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Repair Instructions - Off Vehicle > < Tappet Replacement

Astra J

Valve Stem Oil Seal and Valve Spring Replacement

Special Tools

•  EN-835-A   Installer
•  EN-840   Pliers
•  EN-6086   Spring And Wedge Replacer Kit
•  EN-6086-4   Shaft
•  EN-6086-6   Support
•  EN-6086-7   Lever
•  EN-6086-8   Handle
•  EN-6086-11   Demounting Piece
•  EN-6086-12   Adapter
•  EN-6086-17   Hose
•  EN-6086-100-1   Mounting Piece
•  EN-6086-100-10   Plunger
•  EN-46791   Adapter
•  EN-46783   Thread Adapter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the 16 valve lifters. Refer to Valve Lifter Replacement .

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2. Remove the 2 cylinder head guide sleeves (1).

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3. Install the EN-6086   replacer kit .
  •  Install the 2 EN-6086-6   support (1)
  •  Install the EN-6086-8   handle (2) with the EN-6086-4   shaft (3).

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Note:  Blind hole thread, note injector stud length.
4. Install the fuel injector stud (5).
5. Install the EN-46791   adapter (3) and the EN-46783   thread adapter (2) with the fuel injector (4) and fuel injector bracket to the cylinder 1.

Caution: Refer to Fastener Caution .
6. Install the fuel injector bracket nut (6) and tighten to 20 N·m (15 lb ft) .
7. Install the EN-6086-17   hose (1).

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8. Install the EN-6086-7   lever (3) to the EN-6086-8   handle (1).
9. Install the EN-6086-12   adapter (2) and EN-6086-11   demounting piece (4) to the lever (3).
10. Subject cylinder 1 with compressed air.

Note:  The EN-6086-11   demounting piece must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components.
11. Press down the valve springs and the upper valve spring retainers until the valve keys are discharged from spring load. Remove the valve keys.
12. Remove the valve spring retainer and valve spring.

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13. Remove the valve stem oil seal. Use the EN-840   pliers (1).

Installation Procedure


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1. Install the NEW valve stem seal (3) to the valve shaft (2).
2. Use the EN-835-A   installer (2) to push down the valve stem oil seal.
3. Install the valve spring and the valve spring retainer.

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4. Prepare the EN-6086-100-1   mounting piece for the valve key installation. The mounting piece must be assembled in the following order:
  •  Support (6)
  •  Bushing (5)
  •  Spring (4)
  •  EN-6086-100-10   plunger (3)
  •  Screw connection (2)
  •  Lever adapter (1)

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5. Install the valve keys (1) to the mounting piece (2) as shown and fix them with the bushing.

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6. Install the EN-6086-100-1   mounting piece (1) to the lever.
7. Push the mounting piece slightly down until the valve keys are engaged in evidence.
8. Repeat the procedure for additional intake valve spring cylinder 1.
9. Convert the EN-6086   replacer kit for the exhaust valves cylinder 1.

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10. Remove the EN-6086-17   hose (1).
11. Remove the fuel injector bracket nut (6).
12. Remove the EN-46791   adapter (3) and the EN-46783   thread adapter (2) with the fuel injector (4) and fuel injector bracket from the cylinder 1.
13. Remove the fuel injector stud (5).
14. Repeat the procedure for all additional valve springs.

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15. Remove the EN-6086   replacer kit .
  •  Remove the EN-6086-8   handle (2) with the EN-6086-4   shaft (3).
  •  Remove the 2 EN-6086-6   supports (1).

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16. Install the 2 cylinder head guide sleeves (1).
17. Install the 16 valve lifters. Refer to Valve Lifter Replacement .

Repair Instructions - Off Vehicle > < Tappet Replacement