Replace All Valve Stem Seals (Cylinder Head Installed) Opel Corsa D

Remove

1. 1. Open bonnet
2. 2. Remove air cleaner housing • Disconnect intake air temperature wiring harness plug (1) • In the Z14XEP version with automatic transmission, if present, detach vacuum hose (2) from air intake pipe • Detach engine vent hose from air intake pipe – Release clamp (3) • Detach air intake pipe from throttle valve module – Release clamp (4) • Pull air intake pipe (5) from air cleaner housing • Press air cleaner housing from rubber bearings – Press air cleaner housing upward (arrow) – Press air cleaner housing inward (arrow)

3. 3. Unclip coolant hose (2)
4. 4. Disconnect 3 wiring harness plugs • Camshaft sensor (1) • Coolant temperature sensor (4) • Oil pressure switch (5)
5. 5. Unclip wiring trough (3) from cylinder head cover • Set aside to the rear
6. 6. Remove 2 engine vent hoses (2) from cylinder head cover • Undo 2 clamps
7. 7. Remove ignition module • Disconnect cooling module wiring harness plug (4) • Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow • Unscrew 2x bolts (6) • Remove ignition module (5) from spark plugs with KM-6009 (3)

Important. Do not tilt

8. 8. Detach cylinder head cover (7) from cylinder head • Unscrew 13x bolts

9. 9. Remove gasket remnants and clean sealing surfaces

10. 10. Move crankshaft in direction of engine rotation to just before "cylinder 1 TDC of combustion stroke" • The marking (3) on the crankshaft belt pulley is just before the cast projection (2) on the timing case • In this position, the cams (1) of cylinder 1 are just before "TDC of combustion stroke" (both cams point outwards)
11. 11. Remove closure bolt of chain tensioner (1) from timing case
12. 12. Lock chain tensioner with KM-955-1 (2) • Apply tension to intake camshaft in the direction of engine rotation via hexagon (direction of arrow)

13. 13. Detach sliding rail (1) from cylinder head • Unscrew 2x bolts
14. 14. Remove camshaft sprockets • Unscrew 2x bolts (2) – Counterhold with open-ended wrench against the hexagon of the camshafts (3) • Take out camshaft sprockets
15. 15. Note marking before dismantling camshaft bearing cap Marking, exhaust camshaft = 1 - 3 - 5 - 7 - 9 Marking, intake camshaft = 2 - 4 - 6 - 8 - 10
16. 16. Remove exhaust camshaft • Slacken camshaft bearing caps in stages 1/2 to 1 turn • Unscrew 10x bolt • Take out camshaft bearing caps – Set aside in the correct order • Remove exhaust camshaft

Note. When releasing the camshaft bearing caps, ensure that the camshaft is seated evenly on the bearing seats

17. 17. Remove intake camshaft • Slacken camshaft bearing caps in stages 1/2 to 1 turn • Unscrew 10x bolt • Take out camshaft bearing caps – Set aside in the correct order • Remove intake camshaft

Note. When releasing the camshaft bearing caps, ensure that the camshaft is seated evenly on the bearing seats

18. 18. Remove roller cam follower and hydraulic valve lifter • Mark assignments
19. 19. Clean all parts
20. 20. Remove 4 spark plugs with KM-194-E
21. 21. Raise vehicle by its full height
22. 22. Remove lower engine compartment cover / splash guard
23. 23. Make alignment mark • on crankshaft belt pulley (arrow)

Note. 180° offset to marking TDC of combustion stroke cylinder 1

24. 24. 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
25. 25. Complete assembly set MKM-6086-200 • Insert thrust piece MKM-6086-200-10 (3)

Note. Note manufacturer's provisions

26. 26. Attach automatic valve spring lever MKM-6086 • Attach 2 supports MKM-6086-6 (1) – Push assembly shaft in the supports – Tighten 4x bolts • Install lever arm MKM-6086-7 (2) • Secure installation shaft – Tighten 2x bolts

Note. Align assembly shaft centrally via spark plug bore

Note. Removal head must point towards the intake side

27. 27. Install compressed air adapter • Screw into spark plug thread of cylinder 1 • Apply compressed air to cylinder 1

28. 28. Remove 2 cylinder No.1 intake valve springs • Press valve spring carefully downwards with lever arm (1) • Take out valve cotters, valve discs, valve springs

Note. Removal head (2) must be positioned vertically over the valve stem

Important. Observe correct assignment

Note. Do not use any magnetic tools

29. 29. 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

30. 30. 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 – Insert valve cotters – Push plastic clamping sleeve in the direction of the valve (arrow)

Important. Insert valve cotters with tapered end towards valve

31. 31. Install valve cotters • Attach assembly head (1) to lever arm • Press valve spring carefully downwards with lever arm (arrow) •

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.

32. 32. Transfer lever arm • Remove lever arm • Detach assembly head • Attach removal head • Install lever arm

Note. Removal head must point towards the exhaust side

33. 33. Remove 2 cylinder No.1 exhaust valve springs • Press valve spring carefully downwards with lever arm • Take out valve cotters, valve discs, valve springs

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

Important. Observe correct assignment

Note. Do not use any magnetic tools

34. 34. 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
35. 35. 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 – Insert valve cotters – Push plastic clamping sleeve in the direction of the valve (arrow)

Important. Insert valve cotters with tapered end towards valve

36. 36. Install valve cotters • Attach assembly head to lever arm • Press valve spring carefully downwards with 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.

37. 37. 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
38. 38. Transfer lever arm • Remove lever arm • Detach assembly head • Attach removal head • Install lever arm
39. 39. Replace 4 valve stem seals, cylinder 4
40. 40. Interrupt compressed air feed
41. 41. Remove crankshaft lock KM-952
42. 42. 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

43. 43. Lock crankshaft with KM-952
44. 44. 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
45. 45. Replace 4 valve stem seals, cylinder 2
46. 46. 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
47. 47. Replace 4 valve stem seals, cylinder 3
48. 48. Interrupt compressed air feed
49. 49. Detach automatic valve spring lever
50. 50. Remove compressed air adapter
51. 51. Slacken crankshaft • Put transmission into neutral • Release handbrake
52. 52. Raise vehicle by its full height
53. 53. Lock crankshaft • Pull timing chain upwards • Turn crankshaft evenly until KM-952 engages • Insert KM-952
54. 54. Lower vehicle by its full height

Install

55. 55. Install 4 spark plugs using KM-194-E 25 Nm
56. 56. Visually check components • Camshafts, camshaft bearing caps, cylinder head, roller cam followers, hydraulic valve lifters
57. 57. 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

58. 58. Clean hydraulic valve lifters and coat with MoS2 sliding paste
59. 59. Insert hydraulic valve lifters in accordance with marked allocation
60. 60. Clean roller cam followers and coat with MoS2 sliding paste
61. 61. Insert roller cam followers in accordance with marked allocation
62. 62. Install intake camshaft • Coat sliding surfaces with MoS2 lubricating paste • Insert intake camshaft • Insert camshaft bearing caps • Install camshaft bearing cover – Tighten 10x bolt 8 Nm

Note. Insert camshaft in such a way that the cams of cylinder 1 are set at "TDC of combustion stroke" (cams point outwards)

Important. Note mark and allocation

Note. Tighten camshaft bearing caps in stages, working in a spiral from inside to outside

63. 63. Install exhaust camshaft • Coat sliding surfaces with MoS2 lubricating paste • Insert exhaust camshaft • Insert camshaft bearing caps • Install camshaft bearing cover – Tighten 10x bolt 8 Nm

Note. Insert camshaft in such a way that the cams of cylinder 1 are set at "TDC of combustion stroke" (cams point outwards)

Important. Note mark and allocation

Note. Tighten camshaft bearing caps in stages, working in a spiral from inside to outside

64. 64. Clean phase sensor disc and camshaft sprocket • Clean the contact surface of the phase sensor disc to the camshaft sprocket • Clean the contact surface of the camshaft sprocket to the phase sensor disc • Lightly coat the bolt collar of the new bolt with engine oil

Note. The following steps are to be performed to avoid rotating the phase sensor disc when tightening the camshaft sprocket

65. 65. Tighten camshaft sprockets hand-tight with new bolts • Screw in 2x bolts – Use new bolts – Tighten hand-tight

Note. It must still be possible to turn the phase sensor disc on the intake camshaft by hand

66. 66. Attach sliding rail to cylinder head • Tighten 2x bolt 8 Nm

67. 67. Turn camshafts by the hexagon (short distance) until KM-953 (1) can be inserted in the grooves of the camshafts • KM-953 must engage as far as the stop in the grooves of the camshafts

Note. Turn camshafts carefully and evenly

68. 68. Turn phase sensor disc (2) in such a way that KM-954 (1) can be inserted on the timing case

69. 69. Attach KM-954 to timing case • Tighten 2x bolts
70. 70. Take KM-955-1 out of chain tensioner

71. 71. Unscrew closure bolt, crankshaft bearing bridge (1)
72. 72. Adjust TDC of combustion stroke of cylinder 1 • Insert KM-952 (2) – Turn crankshaft evenly until KM-952 engages – Marking on the crankshaft belt pulley (4) must align with the cast projection (3) on the timing case
73. 73. Remove locking pin of chain tensioner KM-955-1 • Tighten chain tensioner closure bolt 50 Nm – Use new seal ring
74. 74. Fasten camshaft sprockets • Tighten 2x bolt (2) 10 Nm – Counterhold the camshafts on the hexagon (1)

Note. Tightening torque 10 Nm serves to fix the camshaft sprockets and the phase sensor disc temporarily

Note. First of all tighten bolt of intake camshaft sprocket

75. 75. Remove locking tools KM-954 , KM-953 and KM-952

Note. Locking tools may not be used for counterholding

76. 76. Tighten camshaft sprockets • Tighten 2x bolt 50 Nm + 60° – Use new bolts

Note. Use a second person

77. 77. Timing, Check • Turn crankshaft through 720° – Insert KM-952 • Insert KM-953 into camshafts • Attach KM-954 on phase sensor disc

Note. If km-954 cannot be inserted, the operation "timing, adjust" must be repeated

78. 78. Remove KM-954 and KM-953
79. 79. Raise vehicle by its full height
80. 80. Remove KM-952
81. 81. Tighten closure bolt crankshaft bearing bridge 50 Nm • Replace gasket
82. 82. Lower vehicle by its full height
83. 83. Attach cylinder head cover (1) • Replace gasket (2) • Apply a bead of silicone sealing compound (grey) (dimension I) approx. 2 mm thick to the dividing joints of the cylinder head and timing case • Tighten 13x bolt 8 Nm

Important. Complete assembly work within 10 minutes

Important. Bolts must be checked visually to check whether the elastomer seal is damaged. If the elastomer seal is damaged, the bolt must be replaced with a new one.

84. 84. Install ignition module • Connect ignition module to spark plugs • Tighten 2x bolt 8 Nm • Attach ignition module cover to cylinder head cover • Connect ignition module wiring harness plug
85. 85. Clip wiring trough to cylinder head cover
86. 86. Connect 3 wiring harness plugs • Oil pressure switch • Coolant temperature sensor • Camshaft sensor
87. 87. Clip in coolant hose.
88. 88. Install air cleaner housing • Insert air cleaner housing in rubber bearing • Push air intake pipe onto air cleaner housing • Attach air intake hose to throttle valve module – Fasten clamp • Attach engine vent hose to timing case – Fasten clamp • In the Z14XEP version with automatic transmission, if present, attach vacuum hose to air intake pipe • Disconnect intake air temperature sensor wiring harness plug
89. 89. Close bonnet