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Replace Valve Shaft Seals Opel Astra G

Diesel Engine 8 illustrations ~545 words

Remove

  1. 1. Remove hydraulic valve lifter

Note. See operation "Removing and installing hydraulic valve lifter"

  1. 2. Fit protective caps KM-946 (2)

Note. Attach using injection nozzle traverse fastening bolts

  1. 3. Remove sheathed glow plug • Attach 4 wiring harness plugs (2) – Using KM-717 (1) • Remove 4 sheathed glow plugs – Using KM-980
  1. 4. Have required special tools from MKM-6086 at hand: Assembly head MKM-6086-2 Thrust piece MKM-6086-100-10 Assembly shaft MKM-6086-4 Connecting piece MKM-6086-6 Arm MKM-6086-7 Joint MKM-6086-8 Dismantling head MKM-6086-10 Special pliers MKM-6086-14 Compressed air adapter MKM-6086-15
  2. 5. Attach connecting piece (3) • On external camshaft bearing – loosely screw in M8x40 fastening bolts

Note. Adjust connecting piece prior to assembly such that assembly shaft is positioned as close as possible to the inlet manifold - slide support heads (1) to edge of support feet (2) and fix to underside using clamping screw (arrow).

  1. 6. Set engine to no.1 cylinder "Ignition TDC" • Vehicles with manual transmission: Select 1st gear • For vehicles with automatic transmission: Move selector lever to position "P" • Apply parking brake • Wheels must be contact with ground
  1. 7. Apply compressed air to cylinder no.1 • Insert KM-928 (1) into sheathed glow plug hole – Cylinder no.1
  2. 8. Finish lever arm (2) assembly • Joint with fastening bolts (4) • Dismantling head (3)
  1. 9. Remove no.1 cylinder valve springs • Compress lever arm in direction of arrow – Dismantling head (1) must be vertical position above valve stem – align at arm or connecting piece if necessary • Remove valve cotters using KM-6086-14 (2) – Do not use magnetic tool to remove valve cotters • Remove valve spring with valve spring plate – Components must not be interchanged during assembly
  1. 10. Remove valve stem seals • Using KM-840 (1)
  2. 11. Install valve stem seals • Slide provided assembly sleeve (3) onto valve stem and apply thin coat of engine oil • Install valve stem seals (2) – Using KM-835-A (4) • Remove assembly sleeves

Install

  1. 12. convert KM-6086 • Remove dismantling head • Attach assembly head – Using MKM-6086-100-10 marked "6C"
  2. 13. Configure assembly head • Unscrew assembly head – Thrust piece holder (1) – Lever holder (5) • Unscrew screw plug (4) – Screw is under spring pressure • Insert thrust piece (2) into thrust piece holder together with spring (3) – Screw into screw plug – Assemble thrust piece holder and lever holder • Insert valve cotters (9) into assembly head (7) – Groove to plastic expansion pin • Fix valve cotters to thrust piece (8) – By moving the plastic expansion pin (6)
  1. 14. Install valve springs • Insert valve springs with valve spring plates • Place assembly head with thrust piece (1) vertically onto valve stem • Push arm down evenly – Ensure that valve cotters are correctly seated
  1. 15. Repeat operation at no.4 cylinder
  2. 16. Turn engine over 180° in engine rotation direction
  3. 17. Repeat operation at cylinders 2 and 3
  4. 18. Detach MKM-6086
  5. 19. Remove KM-928
  6. 20. Remove KM-946
  7. 21. Install sheathed glow plugs • Using KM-980 – Tightening torque 10 Nm / 7.5 lbf. ft. • Attach wiring harness plugs – 4 items
  8. 22. Install hydraulic valve lifter

Note. See operation "Removing and installing hydraulic valve lifter"

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