How to Replace the All Valve Stem Seals Opel Astra H

Spezialwerkzeugliste:

KM-194-E KM-6152 KM-840 MKM-6086 MKM-6086-100-15 MKM-6086-200

Remove

1. 1. Remove camshafts
2. 2. Remove 4x spark plug • Use KM-194-E

Important. Observe correct allocation and sequence

3. 3. Remove 8x roller cam follower, intake side

Important. Observe correct allocation and sequence

4. 4. Remove 8x roller cam follower, exhaust side
5. 5. Engage gear and put the handbrake on

Note. All the wheels must be in contact with the ground

6. 6. Prepare automatic valve spring lever MKM-6086 • Adjust supports • Complete lever arm – With joint, disassembly head • Complete MKM-6086-200 assembly head – Use MKM-6086-100-15 (3). Insert pressure piece "6J".

Note. Fit support heads (1) centrally on support feet (2).

Note. Note manufacturer's provisions.

7. 7. Attach automatic valve spring lever • Attach 2x supports (1) – At position camshaft bearing cap 1 and 5 – Slide assembly shaft (2) with joint into supports – Tighten 4x bolts • Attach lever arm • Secure assembly shaft – Tighten 2x bolts

Note. Align assembly shaft centrally via spark plug bore.

Note. Removal head (3) must point towards the intake side.

8. 8. Install compressed air adapter (4) • Screw into spark plug thread of cylinder 1 • Apply compressed air to cylinder 1
9. 9. Remove 2x intake valve spring, cylinder 1 • Carefully push valve springs downwards – With lever arm • Take out valve cotters, valve discs, valve springs

Note. Removal head (1) must be positioned vertically over the valve stem.

Important. Observe correct assignment.

Note. Do not use any magnetic tools.

Install

10. 10. Renew 2x valve stem seals • Use KM-840 (1) • Place 2x new valve stem seal on to valve stem • Push in to stop – Use KM-6152 (2)

11. 11. Install 2x intake valve spring, cylinder 1 • Insert valve springs, valve disks • Insert valve cotters (1) into assembly head – Slide plastic clamping sleeve (2) in direction of lever arm mount – Push plastic clamping sleeve towards valve • Attach assembly head to lever arm • Carefully push valve springs downwards – with lever arm

Important. Insert valve cotters with tapered end towards valve.

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 pressure is being applied.

12. 12. Check installation position
13. 13. Transfer lever arm • Remove lever arm • Detach assembly head • Attach removal head • Insert lever arm

Note. Removal head must point towards the exhaust side.

14. 14. Remove 2x exhaust valve spring, cylinder 1 • Carefully push valve springs downwards – With lever arm • Take out valve cotters, valve discs, valve springs

Note. Dismantling head must be positioned vertically over the valve stem

Important. Observe correct assignment.

Note. Do not use any magnetic tools.

15. 15. Renew 2x valve stem seals • Use KM-840 • Place 2x new valve stem seal on to valve stem • Push in to stop – Use KM-6152
16. 16. Install 2x exhaust valve spring, cylinder 1 • Insert valve springs, valve disks • Insert valve cotters into assembly head – Push plastic clamping sleeve towards lever arm mounting – Push plastic clamping sleeve towards valve • Attach assembly head to lever arm • Carefully push valve springs downwards – with lever arm

Important. Insert valve cotters with tapered end towards valve.

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 pressure is being applied.

17. 17. Check installation position
18. 18. Transfer compressed air adapter • Interrupt compressed air feed • Unscrew from spark plug thread of cylinder 1 • Screw into spark plug thread, cylinder 4 • Apply compressed air to cylinder 4
19. 19. Transfer lever arm • Detach assembly head – Remove pin • Attach removal head – Insert pin

Note. Removal head must point towards the exhaust side.

20. 20. Remove 2x exhaust valve spring, cylinder 4
21. 21. Renew 2x valve stem seals
22. 22. Install 2x exhaust valve spring, cylinder 4
23. 23. Check installation position
24. 24. Transfer lever arm • Detach lever arm • Detach assembly head • Attach removal head • Attach lever arm

Note. Removal head must point towards the intake side.

25. 25. Remove 2x intake valve spring, cylinder 4
26. 26. Renew 2x valve stem seals
27. 27. Install 2x intake valve spring, cylinder 4
28. 28. Check installation position
29. 29. Interrupt compressed air feed
30. 30. Slacken crankshaft
31. 31. Set cylinder 2 to TDC of combustion stroke • Lift timing chain • Turn crankshaft evenly (180°)

Note. Torsional vibration damper auxiliary marking must be flush with timing case cover marking.

32. 32. Engage gear and put the handbrake on

Note. All the wheels must be in contact with the ground

33. 33. Transfer lever arm • Detach assembly head • Attach removal head

Note. Removal head must point towards the intake side.

34. 34. Transfer compressed air adapter • Unscrew from spark plug thread, cylinder 4 • Screw into spark plug thread of cylinder 2 • Apply compressed air to cylinder 2
35. 35. Remove 2x intake valve spring, cylinder 2
36. 36. Renew 2x valve stem seals
37. 37. Install 2x intake valve spring, cylinder 2
38. 38. Check installation position
39. 39. Transfer lever arm • Detach lever arm • Detach assembly head • Attach removal head • Attach lever arm

Note. Removal head must point towards the exhaust side.

40. 40. Remove 2x exhaust valve spring, cylinder 2
41. 41. Renew 2x valve stem seals
42. 42. Install 2x exhaust valve spring, cylinder 2
43. 43. Check installation position
44. 44. Transfer lever arm • Detach assembly head • Attach removal head

Note. Removal head must point towards the exhaust side.

45. 45. Transfer compressed air adapter • Unscrew from spark plug thread, cylinder 2 • Screw into spark plug thread, cylinder 3 • Apply compressed air to cylinder 3
46. 46. Remove 2x exhaust valve spring, cylinder 3
47. 47. Renew 2x valve stem seals
48. 48. Install 2x exhaust valve spring, cylinder 3
49. 49. Check installation position
50. 50. Transfer lever arm • Detach lever arm • Detach assembly head • Attach removal head • Attach lever arm

Note. Removal head must point towards the intake side.

51. 51. Remove 2x intake valve spring, cylinder 3
52. 52. Renew 2x valve stem seals
53. 53. Install 2x intake valve spring, cylinder 3
54. 54. Check installation position
55. 55. Detach automatic valve spring lever • Loosen assembly shaft – 2x bolts • Detach lever arm • Detach 2x support – 4x bolts • Remove assembly shaft
56. 56. Remove compressed air adapter • Interrupt compressed air feed
57. 57. Slacken crankshaft
58. 58. Adjust TDC of combustion stroke, cylinder 4 • Lift timing chain • Turn crankshaft evenly (180°)

Note. Torsional vibration damper TDC notch must be flush with timing case cover marking.

59. 59. Visually check components • Camshafts, camshaft bearing cap, hydraulic valve lifter, cylinder head, spark plugs
60. 60. Insert 8x roller cam follower, exhaust side • Lightly coat sliding surfaces with engine oil

Important. Observe correct assignment.

61. 61. Insert 8x roller cam follower, intake side • Lightly coat sliding surfaces with engine oil

Important. Observe correct assignment.

62. 62. Install 4x spark plug • Tighten using KM-194-E 25 Nm
63. 63. Install camshafts