Vauxhall Workshop Service and Repair Manuals

  Inspect

Preconditions: All components are cleaned and checked. Cylinder head is attached to assembly device and is upside down.

  Assemble

Lightly coat valve guides with oil and insert in cylinder head in the appropriate sequence. Insert counterhold.

Depending on the combustion chamber design, different counterholds (1 and 2) must be used to secure the valves.

The counterholds and fastening tools to be used can be found in the survey .

  Install

The counterhold KM-6215-2 (1) is only required for cylinder heads with 2 valves per cylinder.

Fit counterhold KM-6215-2 (1). Attach with locking pins KM-6215-3 (3). Turn fixing screws (2).

Turn assembly device over.

Insert lower valve spring cap / valve rotators in the appropriate sequence.

Carefully install valve stem seals (4) with the relevant installers (5).

Insert valve springs and valve spring cap in cylinder head in the appropriate sequence.

Caution

The components of the assembly head must be assembled according to the following instructions.

  Assemble

The assembly head consists of: mount (1), retaining sleeve (2), thrust piece (3), spring (4), screw connection (5) and lever mounting (6). The assembly head must be assembled in the above sequence.

Different thrust pieces are used depending on engine type. The thrust pieces to be used can be found in the survey

The relevant sizes are stamped on the head of the thrust pieces.

Caution

The combinations of support and thrust piece must always be observed, as otherwise the valve cotters cannot be installed or the thrust pieces are damaged.

The support and thrust piece combinations can be found in the survey .

  Assemble

Slide retaining sleeve (2) downwards and insert valve cotters (1) in the assembly head. Slide retaining sleeve (2) upwards, the valve cotters are held in position.

Attach assembly head to lever MKM-6086.

Adjust (align) lever so that the assembly head is positioned vertically above the valve.

Caution

To facilitate installation of the valve cotters, the assembly head (1) should be attached to the valve stem with the thrust piece (2). This prevents damage occurring to the thrust pieces.

  Install

Press down assembly head with lever slowly and carefully until the valve cotters engage audibly in the valve stem. Then check seating of valve cotters.

  Remove

Remove lever (1) and side mounts. Remove counterhold (2) and wooden board.

Detach cylinder head from assembly device.

  Clean

After assembly of all attaching parts the cylinder head must be cleaned thoroughly.

  Install

Install attaching parts and camshaft(s) to cylinder head.