vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Timing Belt Tensioner Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH > < Valve Clearance Adjustment - 1.6L LLU

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Valve Stem Oil Seal and Valve Spring Replacement

Special Tools

•  EN-840   Pliers/Remover
•  EN-958   Installer
•  EN-6086   Basic Kit, Spring and Wedge Replacer
•  EN-6625   Flywheel Holder

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove both camshafts. Refer to Camshaft Replacement .
2. Remove the spark plugs. Refer to Spark Plug Replacement .

Note:  180° offset to marking ignition TDC cylinder number 1.
3. Make alignment mark on the toothed belt drive belt.
4. Turn the crankshaft to ignition TDC marking, cylinder number 1.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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6. Block the crankshaft.
7. Install EN-6625   flywheel holder (1) to the engine block (2).
8. Lower the vehicle.
9. Install the supports.

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10. Tighten one of the support head (1) in the center of the rail (2) with the fastener (3).

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11. Install the EN-6086-5   mounting shaft (1) to one of the EN-6086-6   support (2).
12. Install the second support to the mounting shaft.
13. Install the lever arm bracket to the cylinder head.

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14. Attach the EN-6086-15   pneumatic adapter (1).
  14.1 Attach the adapter to cylinder number 1.
  14.2 Apply compressed air to cylinder number 1.

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15. Attach the EN-6086-7   lever arm (3).
  15.1 Complete the lever arm with the EN-6086-8   joint (1) and the EN-6086-11   removal head (2).
Note:  Removal head must point toward the intake side.
  15.2 Slide assembly on installation shaft over the 1st cylinder.
16. Remove the intake valve springs, 1st cylinder.
Note:  Removal head must be positioned vertically over the valve stem.
  16.2 Carefully push the valve springs down using the EN-6086-7   lever arm .
Note:  Observe correct assignment.
  16.3 Remove the valve keepers.
  16.4 Remove the valve head and the valve springs.

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17. Remove the valve stem seals.
  Remove the valve stem seals with the EN-840   remover (1).
18. Install the valve stem seals.
  18.1 Coat the valve stem with engine oil.
  18.2 Connect the new valve stem seals onto valve stem.
  18.3 Using the EN-958   installer , drive home to limit stop.

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Note:  Note manufacturer provisions.
19. Complete the EN-6086-200-1   assembly head .
  19.1 Use the EN-6086-200-10   thrust piece .
  19.2 Put together the assembly head consisting of mount (1), fixing sleeve (2), thrust piece (3), spring (4), screw fixing (5) and lever mount (6).

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20. Install the intake valve springs, 1st cylinder.
  20.1 Insert the valve springs and valve head.
Note:  Insert the valve cotters with the tapered end toward the valve.
  20.2 Insert the valve cotters (1) in the EN-6086-200-1   assembly head .
•  Slide the plastic clamping sleeve (2) in the direction of the lever arm mount.
•  Push the plastic clamping sleeve toward the valve.
Note:  Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.
  20.3 Attach the assembly head to the lever arm.
  20.4 Carefully push the valve spring down using the EN-6086-7   lever arm .

Note:  Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.
21. Inspect installation position.
  Inspect seating of the valve keepers (visual inspection).
22. Transfer the EN-6086-7   lever arm .
  22.1 Remove the lever arm.
  22.2 Detach the assembly head.
Note:  Removal head must point toward the exhaust side.
  22.3 Attach the removal head.
  22.4 Install the lever arm.
23. Remove the exhaust valve springs, 1st cylinder.
  23.1 Carefully push the valve springs down using the EN-889-12   lever arm .
Note:  Removal head must be positioned vertically over the valve stem.
  23.2 Remove the valve keepers
Note:  Observe correct assignment.
  23.3 Remove the valve head and valve springs.
24. Replace the valve stem seals.
  24.1 Pull off with the EN-840   remover .
  24.2 Coat the valve stem with engine oil.
  24.3 Connect the new valve stem seals onto the valve stem.
  24.4 Using the EN-958   installer , drive home to limit stop.
25. Attach the EN-6086-7   lever arm .
  25.1 Insert the valve springs and valve head.
  25.2 Insert the valve wedges in the EN-889-2   assembly head .
• 
     Note:  Insert the valve cotters with the tapered end toward the valve.
•  Push the plastic clamping sleeve toward the lever arm mounting.
•  Push the plastic clamping sleeve toward the valve.
Note:  Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.
  25.3 Attach the assembly head to the lever arm.
Note:  Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.
  25.4 Carefully push the valve spring down using the EN-889-12   lever arm .
26. Inspect installation position.
  Inspect seating of the valve keepers (visual inspection).
27. Transfer the EN-6086-15   pneumatic adapter .
  27.1 Interrupt the compressed air feed.
  27.2 Remove the adapter from cylinder number 1.
  27.3 Install the adapter to cylinder number 4.
  27.4 Apply compressed air to cylinder number 4.
28. Replace the valve stem seal of cylinder 4 by analogy with step 14 - 21.
29. Remove the EN-6086-15   pneumatic adapter .
  29.1 Interrupt the compressed air feed.
  29.2 Remove the adapter from cylinder number 4.
30. Raise and support the vehicle.
31. Remove EN-6625   holder from the engine block.
32. Set the crankshaft to ignition TDC of cylinder 3.

Note:  Alignment marking on toothed belt drive wheel must align with marking on rear toothed belt cover.
33. Turn crankshaft evenly by 180°.
34. Block the crankshaft.
35. Install EN-6625   holder to the engine block.
36. Lower the vehicle.
37. Replace the valve stem seal of cylinders 2 and 3 by analogy with step 7 to step 21.
38. Remove the EN-6086-15   pneumatic adapter .
  38.1 Interrupt the compressed air feed.
  38.2 Remove the adapter from cylinder number 3.
39. Remove the EN-6086   automatic valve spring lever .
  39.1 Release the installation shaft.
  39.2 Remove both supports with the installation shaft.
  39.3 Remove the installation head from the lever arm.

Installation Procedure

1. Raise the vehicle.
2. Remove EN-6625   holder from the engine block.

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3. Set the engine to 60° (measurement l) before TDC.
4. Set the crankshaft in direction of engine rotation to 60° (measurement l) before TDC.
5. Install the spark plugs. Refer to Spark Plug Replacement .
6. Install both camshafts. Refer to Camshaft Replacement .

Timing Belt Tensioner Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH > < Valve Clearance Adjustment - 1.6L LLU