vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace valve springs > < Replace camshaft adjuster solenoid valve (intake and exhaust side)

Corsa D

Replace all valve stem seals (cylinder head installed)

  Remove

1.   Open bonnet
2.   Remove air cleaner housing LUREF_1.gif
3.   Remove ignition module
4.   Remove cylinder head cover
5.   Remove 4x spark plug
6.   Remove gasket remnants and clean sealing surfaces
7.   Remove intake camshafts and exhaust camshaft LUREF_1.gif
8.   Remove hydraulic valve lifter LUREF_1.gif
Note:   Note removal sequence.
9.   Remove lower engine compartment cover / splash guard
10.   Adjust TDC of combustion stroke of cylinder 1
•   Marking on the ribbed V-belt pulley marker bore (2) must align with the cast projection (1) on the timing case
Object Number: 13408684 Size: DEFAULT


11.   Make alignment mark
•   On crankshaft belt pulley
Note:   180° offset to marking TDC of combustion stroke cylinder 1.
12.   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
13.   Complete assembly set MKM-6086-200
•   Insert thrust piece MKM-6086-200-11 (3)
Note:   Follow manufacturer's instructions
Object Number: 2411369 Size: DEFAULT


14.   Attach automatic valve spring lever MKM-6086
•   Attach 2 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
– Insert 2x bolt
Object Number: 2410443 Size: DEFAULT


15.   Install compressed air adapter
•   Screw into spark plug thread of cylinder 1
•   Apply compressed air to cylinder 1
16.   Remove 2 cylinder no.1 intake valve springs
•   Press valve spring carefully downwards with lever arm (1)
Note:   Removal head (2) must be positioned vertically over the valve stem.
Important:   Note allocation.
•   Take out valve cotters, valve discs, valve springs
Note:   Do not use any magnetic tools.
Object Number: 2410449 Size: DEFAULT


17.   Replace 2x valve stem seals
•   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


18.   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 split cotters with the narrow part facing the valve.
– Insert valve cotters
– Push plastic clamping sleeve in the direction of the valve (arrow)
Object Number: 2410505 Size: DEFAULT


19.   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.
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.
•   Press valve spring carefully downwards with lever arm (arrow)
Object Number: 2410506 Size: DEFAULT


20.   Transfer lever arm
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
Note:   Removal head must point towards the exhaust side.
21.   Remove 2 cylinder No.1 exhaust valve springs
•   Press valve spring carefully downwards with lever arm
Note:   Removal head must be vertical above the valve stem.
Important:   Note allocation.
•   Take out valve cotters, valve discs, valve springs
Note:   Do not use any magnetic tools.
22.   Replace 2x valve stem seals
•   Remove with KM-840
•   Place new valve stem seal on to valve stem
•   Drive in as far as the stop with KM-958
23.   Install 2 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 split cotters with the narrow part facing the valve.
– Insert valve cotters
– Push plastic clamping sleeve in the direction of the valve (arrow)
Object Number: 2410505 Size: DEFAULT


24.   Install valve cotters
•   Attach assembly head to lever arm
Important:   Assembly head must stand vertically above valve stem. Valve cotters must engage audibly.
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.
•   Press valve spring carefully downwards with lever arm
25.   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
26.   Transfer lever arm
•   Remove lever arm
•   Detach assembly head
•   Attach removal head
•   Install lever arm
27.   Replace 4 valve stem seals, cylinder 4
28.   Interrupt compressed air feed
29.   Remove crankshaft lock KM-952
30.   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.
31.   Lock crankshaft with KM-952
32.   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
33.   Replace 4 valve stem seals, cylinder 2
34.   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
35.   Replace 4 valve stem seals, cylinder 3
36.   Interrupt compressed air feed
37.   Detach automatic valve spring lever
38.   Remove compressed air adapter
39.   Lock crankshaft
•   Pull timing chain upwards
•   Turn crankshaft evenly until KM-952 engages
•   Insert KM-952

  Install

40.   Visually check components
•   Camshafts, camshaft bearing caps, cylinder head, roller cam followers, hydraulic valve lifters
41.   Check camshaft and camshaft bearing for wear
Note:   If the camshaft bearings are faulty, the cylinder head must be replaced. When replacing the camshaft, the roller cam followers (1) and hydraulic valve lifters (2) must be replaced.
Object Number: 2399412 Size: DEFAULT


42.   Clean hydraulic valve lifters and coat with MoS2 sliding paste
43.   Insert hydraulic valve lifters in accordance with marked allocation
44.   Clean roller cam followers and coat with MoS2 sliding paste
45.   Insert roller cam followers in accordance with marked allocation
46.   Install intake camshaft and exhaust camshaft LUREF_1.gif
47.   Clean phase sensor disk and camshaft sprocket
Note:   The following steps are to be performed to avoid rotating the phase sensor disc when tightening the camshaft sprocket.
•   Clean the contact surface of the phase sensor disk to the camshaft sprocket
•   Clean the contact surface of the camshaft sprocket to the phase sensor disk
•   Lightly coat the bolt collar of the new bolt with engine oil
48.   Attach camshaft sprockets to camshafts LUREF_1.gif
49.   Timing, Adjust
50.   Attach sliding rail to cylinder head
•   Tighten 2x bolt 8 Nm
51.   Timing, Check
•   Turn crankshaft through 720°
– Insert locking tool KM-952
•   Insert locking tool KM-953-A into camshaft
•   Attach locating tool EN-49977-100 to phase sensor discs
Note:   If EN-49977-100 cannot be inserted, the operation "timing, adjust" must be repeated LUREF_1.gif
52.   Detach locating tool EN-49977-100 and locking tool KM-953-A
53.   Remove locking tool KM-952
54.   Tighten closure bolt crankshaft bearing bridge 50 Nm
•   Replace gasket
55.   Attach cylinder head cover
56.   Install 4x spark plug
57.   Install ignition module
58.   Install air cleaner housing LUREF_1.gif
59.   Close bonnet

Replace valve springs > < Replace camshaft adjuster solenoid valve (intake and exhaust side)