vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Check and adjust valve play > < Camshaft Adjuster, Replace

Astra H

Replace all valve stem seals (cylinder head installed)

  Remove

1.   Remove camshafts
2.   Remove spark plugs with KM-194-E
3.   Raise vehicle
4.   Remove right engine splash guard (2)
•   Unscrew 4x bolts (1)
•   Remove 2x body-bound rivets (3)
Object Number: 3446244 Size: DEFAULT


5.   Make alignment mark
•   on crankshaft belt pulley (arrow)
Note:   180° offset to marking TDC of combustion stroke cylinder 1
Object Number: 2410503 Size: DEFAULT


6.   Prepare automatic valve spring lever MKM-6086
•   Adjust MKM-6086-6 supports (2)
– Adjust support heads (1) so that they are centred in respect of the support feet (2) and tighten
•   Complete lever arm MKM-6086-7
– with joint MKM-6086-8 and dismantling head MKM-6086-10
7.   Complete assembly set MKM-6086-200
•   Insert thrust piece MKM-6086-200-10 (3)
Note:   Note manufacturer's provisions
Object Number: 2411369 Size: DEFAULT


8.   Attach automatic valve spring lever MKM-6086
•   Attach supports ( MKM-6086-6 1)
– Push assembly shaft in the supports
Note:   Align assembly shaft centrally via spark plug bore
– Tighten 4x bolts
•   Install lever arm MKM-6086-7 (2)
Note:   Removal head must point towards the intake side
•   Secure installation shaft
– Tighten 2x bolts
9.   Install compressed air adapter
•   Screw into spark plug thread of cylinder 1
•   Apply compressed air to cylinder 1
Object Number: 2410443 Size: DEFAULT


10.   Remove intake valve springs, cylinder 1
•   2 off
•   Press valve spring carefully downwards with lever arm (1)
Note:   Removal head (2) must be positioned vertically over the valve stem
Important:   Observe correct assignment
•   Take out valve cotters, valve discs, valve springs
Note:   Do not use any magnetic tools
Object Number: 2410449 Size: DEFAULT


11.   Replace valve stem seals
•   2 off
•   Remove with KM-840
•   Place new valve stem seal on to valve stem
•   Drive in as far as the stop with KM-958
Object Number: 2410450 Size: DEFAULT


12.   Install intake valve springs, cylinder 1
•   Insert valve springs and valve heads
•   Insert valve cotters into assembly head (1)
– Slide plastic clamping sleeve (2) in direction of lever arm mount
Important:   Insert valve cotters with tapered end towards valve
– Insert valve cotters
– Push plastic clamping sleeve in the direction of the valve (arrow)
Object Number: 2410505 Size: DEFAULT


13.   Install valve cotters
•   Attach assembly head (1) to lever arm
Important:   Assembly head must stand vertically above valve stem. Valve cotters (2) must engage audibly
•   Press valve spring carefully downwards with lever arm (arrow)
Important:   Do not make a 2nd attempt without checking that both valve cotters are seated in the assembly head. Check seat of valve cotters. Ensure compressed air is being applied.
•  
Object Number: 2410506 Size: DEFAULT


14.   Transfer lever arm
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
Note:   Removal head must point towards the exhaust side
15.   Remove exhaust valve springs, cylinder 1
•   2 off
•   Press valve spring carefully downwards with lever arm
Note:   Removal head must be positioned vertically over the valve stem
Important:   Observe correct assignment
•   Take out valve cotters, valve discs, valve springs
Note:   Do not use any magnetic tools
16.   Replace valve stem seals
•   2 off
•   Remove with KM-840
•   Place new valve stem seal on to valve stem
•   Drive in as far as the stop with KM-958
17.   Install exhaust valve springs, cylinder 1
•   Insert valve springs and valve heads
•   Insert valve cotters into assembly head (1)
– Slide plastic clamping sleeve (2) in direction of lever arm mount
Important:   Insert valve cotters with tapered end towards valve
– Insert valve cotters
– Push plastic clamping sleeve in the direction of the valve (arrow)
Object Number: 2410505 Size: DEFAULT


18.   Install valve cotters
•   Attach assembly head to lever arm
Important:   Assembly head must stand vertically above valve stem. Valve cotters must engage audibly
•   Press valve spring carefully downwards with lever arm
Important:   Do not make a 2nd attempt without checking that both valve cotters are seated in the assembly head. Check seat of valve cotters. Ensure compressed air is being applied.
•  
19.   Transfer compressed air adapter
•   Interrupt compressed air feed
•   Unscrew from spark plug thread of cylinder 1
•   Screw into spark plug thread of cylinder 4
•   Apply compressed air to cylinder 4
20.   Transfer lever arm
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
21.   Replace valve stem seals, cylinder 4
•   4 off
22.   Interrupt compressed air feed
23.   Remove crankshaft lock KM-952
24.   Adjust TDC of combustion stroke of cylinder 3
•   Pull timing chain upwards
•   Turn crankshaft evenly (180°)
Note:   Marking made as aid on crankshaft belt pulley must align with cast projection on timing case
25.   Lock crankshaft with KM-952
26.   Transfer compressed air adapter
•   Interrupt compressed air feed
•   Unscrew from spark plug thread of cylinder 4
•   Screw into spark plug thread of cylinder 2
•   Apply compressed air to cylinder 2
27.   Replace valve stem seals, cylinder 2
•   4 off
28.   Transfer compressed air adapter
•   Interrupt compressed air feed
•   Unscrew from spark plug thread of cylinder 2
•   Screw into spark plug thread of cylinder 3
•   Apply compressed air to cylinder 3
29.   Replace valve stem seals, cylinder 3
•   4 off
30.   Interrupt compressed air feed
31.   Detach automatic valve spring lever
32.   Remove compressed air adapter
33.   Slacken crankshaft
•   Put transmission into neutral
•   Release handbrake
34.   Raise vehicle
35.   Lock crankshaft
•   Pull timing chain upwards
•   Turn crankshaft evenly until KM-952 engages
•   Insert KM-952
36.   Lower vehicle

  Install

37.   Install spark plugs with KM-194-E 25 Nm
38.   Visually check components
•   Camshafts, camshaft bearing caps, cylinder head, roller cam followers, hydraulic valve lifters
39.   Install hydraulic rams, roller cam followers and camshafts LUREF_1.gif

Check and adjust valve play > < Camshaft Adjuster, Replace