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Replace All Valve Stem Seals (Cylinder Head Installed) Opel Meriva A

DOHC Petrol Engine 9 illustrations ~916 words

Remove

  1. 1. Remove camshafts
  2. 2. Remove spark plugs with KM-194-E
  3. 3. Raise vehicle
  4. 4. Remove right engine splash guard (2) • Unscrew 4x bolts (1) • Remove 2x body-bound rivets (3)
  1. 5. Make alignment mark • On crankshaft belt pulley (arrow)

Note. 180° offset in respect of the marking, ignition TDC cylinder no. 1

  1. 6. Prepare automated valve spring lever MKM-6086 • Adjust supports MKM-6086-6 (2) – Adjust support heads (1) centrally in respect of the support feet (2) and tighten • Complete lever arm MKM-6086-7 – With joint MKM-6086-8 and removal head MKM-6086-10
  2. 7. Complete assembly kit MKM-6086-200 • Insert thrust piece MKM-6086-200-10 (3)

Note. Note manufacturer's provisions

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

Note. Align assembly shaft so that it is centred over spark plug bore

Note. Removal head must point towards the intake side

  1. 9. Install compressed air adapter • Screw into spark plug thread, cylinder no. 1 • Apply compressed air to 1st cylinder
  1. 10. Remove cylinder no.1 intake valve springs • 2 off • Carefully push valve springs downward with lever arm (1) • Remove valve cotters, valve heads, valve springs

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

Important. Observe correct assignment

Note. Do not use magnetic tools

  1. 11. Replace valve stem seals • 2 off • Remove with KM-840 • Attach new valve stem seal to valve stem • Drive in as far as the stop with KM-958
  1. 12. Install intake valve springs, cylinder no.1 • Insert valve springs and valve heads • Insert valve cotters into assembly head (1) – Push plastic clamping sleeve (2) towards lever arm mounting – Insert valve cotters – Slide plastic clamping sleeve in direction of valve (arrow)

Important. Insert valve cotters with tapered end towards valve

  1. 13. Install valve cotters • Attach assembly head (1) to lever arm • Carefully push valve springs downwards with lever arm (arrow) •

Important. Assembly head must be positioned vertically above valve stem. Valve cotters (2) must engage audibly

Important. Do not undertake a 2nd attempt without checking that both valve cotters are seated in the assembly head. Check seat of valve cotters. Ensure that compressed air is being applied

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

Note. Removal head must point towards the exhaust side

  1. 15. Remove exhaust valve springs, cylinder no.1 • 2 off • Carefully push valve springs downwards with lever arm • Remove valve cotters, valve heads, valve springs

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

Important. Observe correct assignment

Note. Do not use magnetic tools

  1. 16. Replace valve stem seals • 2 off • Remove with KM-840 • Attach new valve stem seal to valve stem • Drive in as far as the stop with KM-958
  2. 17. Install exhaust valve springs, cylinder no.1 • Insert valve springs and valve heads • Insert valve cotters into assembly head (1) – Push plastic clamping sleeve (2) towards lever arm mounting – Insert valve cotters – Slide plastic clamping sleeve in direction of valve (arrow)

Important. Insert valve cotters with tapered end towards valve

  1. 18. Install valve cotters • Attach assembly head to lever arm • Carefully push valve springs downwards with lever arm •

Important. Assembly head must stand vertically above valve stem. Valve cotters must engage audibly

Important. Do not undertake a 2nd attempt without checking that both valve cotters are seated in the assembly head. Check seat of valve cotters. Ensure that compressed air is being applied

  1. 19. Transfer compressed air adapter • Interrupt compressed air feed • Unscrew from spark plug thread, cylinder no. 1 • Screw into spark plug thread, cylinder no. 4 • Apply compressed air to cylinder no. 4
  2. 20. Transfer lever arm • Remove lever arm • Detach assembly head • Attach removal head • Install lever arm
  3. 21. Replace valve stem seals, cylinder no. 4 • 4 off
  4. 22. Interrupt compressed air feed
  5. 23. Remove crankshaft lock KM-952
  6. 24. Adjust ignition TDC of cylinder no. 3 • Pull timing chain upwards • Turn crankshaft evenly (180°)

Note. Positioning mark on crankshaft belt pulley must align with lug on timing case

  1. 25. Transfer compressed air adapter • Interrupt compressed air feed • Unscrew from spark plug thread, cylinder no. 4 • Screw into spark plug thread, cylinder no. 2 • Apply compressed air to 2nd cylinder
  2. 26. Replace valve stem seals, cylinder no. 2 • 4 off
  3. 27. Transfer compressed air adapter • Interrupt compressed air feed • Unscrew from spark plug thread, cylinder no. 2 • Screw into spark plug thread, cylinder no. 3 • Apply compressed air to 3rd cylinder
  4. 28. Replace valve stem seals, cylinder no. 3 • 4 off
  5. 29. Interrupt compressed air feed
  6. 30. Detach automatic valve spring lever
  7. 31. Remove compressed air adapter
  8. 32. Release crankshaft • Select neutral gear • Release handbrake
  9. 33. Raise vehicle
  10. 34. Lock crankshaft • Pull timing chain upwards • Turn crankshaft evenly until KM-952 engages • Insert KM-952
  11. 35. Lower vehicle

Install

  1. 36. Install spark plugs using KM-194-E 25 Nm
  2. 37. Inspect components • Camshafts, camshaft bearing cap, cylinder head, roller cam follower, hydraulic valve lifter
  3. 38. Install hydraulic valve lifter, roller cam follower and camshafts

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