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Replace Valve Stem Seals Opel Zafira B

Diesel Engine 8 illustrations ~572 words

Remove

  1. 1. Remove Hydraulic Valve Lifter

Note. See operation "Hydraulic Valve Lifter, Remove and Install"

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

Note. Fasten with fastening bolts of the injection nozzle traverses

  1. 3. Remove sheathed glow plugs • Remove 4 wiring harness plugs (2) – With KM-717 (1) • Remove 4 sheathed glow plugs – With KM-980
  1. 4. Lay out the special tools required from MKM-6086 in readiness: Assembly head MKM-6086-2 Thrust piece MKM-6086-100-10 Assembly shaft MKM-6086-4 Supports MKM-6086-6 Lever arm MKM-6086-7 Articulated joint MKM-6086-8 Dismantling head MKM-6086-10 Special pliers MKM-6086-14 Compressed air adapter MKM-6086-15
  2. 5. Attach supports (3) • Screw loosely onto outer camshaft bearing – with fastening bolts M8x40

Note. Adjust supports in such a way before assembly that the assembly shaft is positioned as close as possible to the intake manifold - push support heads(1) against the edge of the support feet (2) and fix on the underside with the clamping screw (arrow)

  1. 6. Move engine to 1st cylinder "ignition-TDC" • For vehicles with manual transmission: put into 1st gear • For vehicles with automatic transmission: Put into selector lever position "P" • Apply parking brake • Wheels must be in contact with the ground
  1. 7. Apply compressed air to 1st cylinder • Install KM-928 (1) into glow pencil bore – 1st cylinder
  2. 8. Complete assembly of lever arm (2) • Articulated joint with fixing bolts (4) • Dismantling head (3)
  1. 9. Remove valve springs of 1st cylinder • Press lever arm together in the direction of the arrow – Dismantling head (1) must be vertically above the valve stem – if necessary align via lever arm or supports • Remove valve keeper with KM-6086-14 (2) – Do not use magnetic tools for removing the valve keepers • Remove valve spring with valve spring retainer – Components may not be mixed up during installation
  1. 10. Remove valve stem seals • With KM-840 (1)
  2. 11. Install valve stem seals • Push enclosed assembly sleeve (3) on to valve stem and wet slightly with engine oil • Install valve stem seals (2) – With KM-835-A (4) • Remove assembly sleeve

Install

  1. 12. Retool KM-6086 • Remove dismantling head • Attach assembly head – With thrust piece MKM-6086-100 marked "6C"
  2. 13. Fit assembly head • Unscrew assembly head to dismantle it – Thrust piece holder (1) – Lever holder (5) • Unscrew closure bolt(4) – Bolt is under pressure from spring • Insert thrust piece (2) together with spring (3) into thrust piece holder – Screw in closure bolt – Assemble thrust piece holder and lever holder • Insert valve keepers (9) into assembly head (7) – Groove towards plastic tensioning sleeve • Fix valve keepers on thrust piece (8) – By pushing the plastic tensioning sleeve (6)
  1. 14. Install valve springs • Insert valve springs with valve spring retainers • Place assembly head with thrust piece (1) vertically on to the valve stem • Press lever arm down evenly – Ensure the valve keepers are seated correctly
  1. 15. Repeat operation on cylinder 4.
  2. 16. Turn engine through 180° in the direction of rotation of the engine
  3. 17. Repeat operation on cylinder 2 and 3.
  4. 18. Detach MKM-6086
  5. 19. Remove KM-928
  6. 20. Remove KM-946
  7. 21. Install sheathed glow plugs • with KM-980 – Tightening torque 10 Nm • Attach wiring harness plug – 4 pieces
  8. 22. Install hydraulic valve lifter

Note. See operation "Hydraulic Valve Lifter, Remove and Install"

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