Vauxhall Workshop Service and Repair Manuals

J 312315 Valve Stem Seals, Replace (Z 18 XE, with Air Conditioning, LHD)

  Remove

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow)

5.   Remove upper part of toothed belt cover •   Unscrew 3 bolts (arrows) •   Unclip from rear toothed belt cover

6.   Raise vehicle 7.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 8.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2) 9.   Lower vehicle

10.   Detach front right wheel •   Loosen 4 bolts 11.   Raise vehicle 12.   Remove right front wheel. •   Unscrew 4 bolts 13.   Raise vehicle 14.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

15.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner. •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Remove bolt (1)

16.   Detach crankshaft ribbed V-belt pulley •   Prise front closure plug out of oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

17.   Release lower part of toothed belt cover •   Remove bolt (arrow) •   Unclip from rear toothed belt cover 18.   Lower vehicle

20.   Disconnect camshaft sensor wiring harness plug (1) •   Unclip from bracket 21.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover •   Remove downwards 22.   Remove camshaft sensor (2) •   Unscrew 2 bolts

23.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Fix camshaft sprockets in position. – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) – Use KM-852 (II) 24.   Remove toothed belt •   Release toothed belt tension roller (IV) – Loosen bolt – Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop.

25.   Remove ignition module •   Disconnect wiring harness plug (2) •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt

26.   Release preheater line - throttle valve module (1) •   Unscrew 2 bolts •   Disconnect coolant temperature sensor wiring harness plug (4) •   Unclip wiring harness of mixture regulation heated oxygen sensor (3) 27.   Remove cylinder head cover •   Detach engine vent hose (2) •   Unscrew 10 bolts •   Remove seal 28.   Remove KM-852

29.   Remove exhaust camshaft sprocket •   Remove bolt – Counterhold camshaft at hexagonal section 30.   Remove intake camshaft sprocket •   Remove bolt – Counterhold camshaft at hexagonal section 31.   Release rear toothed belt cover •   Unscrew 2 bolts

32.   Loosen upper rear toothed belt cover •   Unscrew 2 bolts 33.   Remove exhaust camshaft •   Remove camshaft bearing cap Note:   Note identification – Unscrew 10 bolts •   Release camshaft bearing caps in stages, working in a spiral pattern from the outside inwards Note:   Camshaft must be evenly released from the bearing seats – 1/2 to 1 turn •   Remove camshaft seal ring

34.   Remove 8x hydraulic valve lifters (2) with KM-845 (1) Note:   Observe allocation.

40.   Apply positioning marks to toothed belt drive gear •   180° offset to no.1 cylinder TDC mark (Zünd-OT-Zylinder-1) (arrows)

43.   Assemble automatic valve spring compressor Note:   Observe manufacturer's instructions •   Adjust supports – Adjust support heads (1) so that they are centred on support feet (2) and tighten •   Assemble lever arm with joint and removal head •   Assemble installation kit MKM-6089-200 – Insert thrust piece 5b (3)

44.   Attach automatic valve spring compressor •   Attach supports to camshaft bearing cap positions 1 and 4 – Slide installation shaft into supports Note:   Align installation shaft so that it is centred on spark plug bore – Tighten 4 bolts •   Install lever arm (1) – Removal head (2) must face intake side •   Secure installation shaft – Tighten 2 bolts 45.   Install compressed air adapter (3) •   Screw into spark plug thread of 1st cylinder •   Apply compressed air to 1st cylinder

46.   Remove 2x cylinder no.1 intake valve springs Note:   Do not use magnetised tool. •   Carefully push valve spring down with lever arm – Removal head must be vertically above the valve stem •   Remove valve keepers, valve head, valve spring Note:   Observe allocation. 47.   Replace 2x valve stem seals •   Detach using KM-840 (1) •   Attach new valve stem seal to valve stem •   Drive in to stop using KM-835-A (2)

48.   Install intake valve springs for 1st cylinder •   Insert valve spring, valve head •   Insert valve keepers (1) in assembly head – Slide clamping sleeve (2) in direction of lever arm mount – Insert valve keepers with taper facing the valve. – Push clamping sleeve towards valve •   Attach assembly head to lever arm •   Carefully push valve spring down with lever arm – Assembly head must be vertically above the valve stem – The valve keepers must audibly engage

51.   Remove 2x cylinder no.1 exhaust valve springs Note:   Do not use magnetised tool. •   Carefully push valve springs downwards – With lever arm – Removal head (1) must be vertically above the valve stem •   Remove valve keepers, valve head, valve spring Note:   Observe allocation.

56.   Transfer lever arm •   Loosen installation shaft – Loosen 2 bolts •   Remove lever arm •   Detach assembly head •   Attach removal head •   Install lever arm •   Secure installation shaft – Tighten 2 bolts

65.   Transfer compressed air adapter •   Unscrew from spark plug thread of 4th cylinder •   Screw into spark plug thread of 2nd cylinder •   Apply compressed air to 2nd cylinder

  Install

76.   Position crankshaft •   Set crankshaft to 60° before no.1 cylinder TDC of combustion stroke

77.   Lower vehicle 78.   Clean cylinder head •   Remove gasket remnants 79.   Insert 8x hydraulic valve lifters •   Coat sliding surfaces with engine oil Note:   Observe allocation. 80.   Install intake camshaft •   Coat sliding surfaces with engine oil •   Apply sealant in the area of the camshaft seal ring (arrows) Note:   Do not apply sealant in vicinity of oil channels. Complete installation work within 10 minutes. •   Insert camshaft, camshaft bearing cap Note:   Observe identification and allocation •   Tighten 10x bolts for camshaft bearing caps 8 Nm – Tighten in stages, working in a spiral pattern from the inside outwards •   Remove excess sealant

82.   Install exhaust camshaft •   Coat sliding surfaces with engine oil •   Apply sealant in the area of the camshaft seal ring (arrows) Note:   Do not apply sealant in vicinity of oil channels. Complete installation work within 10 minutes. •   Insert camshaft, camshaft bearing cap Note:   Observe identification and allocation •   Tighten 10x bolts for camshaft bearing caps 8 Nm – Tighten in stages, working in a spiral pattern from the inside outwards •   Remove excess sealant 83.   Install intake camshaft seal ring •   Replace seal ring •   Coat seal lip with grease •   Place seal ring on camshaft journal •   Install camshaft seal ring – With KM-422 (1), bolt and camshaft sprocket washer

89.   Put toothed belt in place •   Position toothed belt Note:   Tensioned side (I) must be taut.

90.   Tension toothed belt •   Tension toothed belt tension roller – Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop •   Fasten toothed belt tension roller bolt (1) 91.   Remove KM-852

92.   Timing, Check •   Turn crankshaft in direction of engine rotation at the crankshaft ribbed V-belt pulley bolt (720°) •   Set crankshaft to mark. – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Use KM-852 (II) – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) 93.   Remove KM-852

94.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) of toothed belt tension roller is aligned with the appropriate notch mark – Adjust used toothed belts to the marking USED – Adjust new toothed belts to the marking NEW (2) •   Tighten toothed belt tension roller bolt 20 Nm 95.   Check toothed belt tension •   Turn crankshaft (720°) •   Pointer on the toothed belt tension roller and notch mark must align. – Adjust used toothed belts to the marking USED – Adjust new toothed belts to the marking NEW 96.   Clean threads •   Camshaft sensor to cylinder head

101.   Install cylinder head cover •   Replace gasket (2) •   Apply sealant (1) Note:   Complete assembly operations within 10 minutes •   Tighten 10x bolts 8 Nm •   Attach engine vent hose 102.   Fasten preheater line - throttle valve module •   Tighten 2x bolts 8 Nm •   Connect coolant temperature sensor wiring harness plug •   Clip in wiring harness of mixture regulation heated oxygen sensor 103.   Connect wiring harness plug from camshaft sensor •   Clip to bracket