Carrying out work using the Opel KM-565 device
Removal
1. Using the special device KM-565 (or an equivalent substitute), the valve drive levers and valve clearance compensators can be removed without first removing the camshaft.
2. Set the parking brake, then jack up the front of the vehicle and place it on supports. Remove the right front wheel, and if so equipped, also remove the crankcase guard.
3. Remove the timing cover (see Removal and installation the timing cover).
4. Turn the crankshaft in the normal direction by the pulley bolt until the cam of the first valve, the drive components of which are subject to maintenance, turns with the working lug upward.
5. Secure the device on top of the valve timing case, aligning its tip with the end of the corresponding valve stem. Screw the pin of the device into one of the housing bolt holes until the valve is recessed enough to enable the lever of its drive to be removed from under the camshaft. Now you can remove the hydraulic compensator and remove the oil deflector cap.
6. Carefully check the status of all components (see below Examination), - replace worn or damaged ones.
Installation
1. Lubricate the valve drive lever and its clearance compensator with clean engine oil and insert the latter into its seat in the cylinder head. Install the valve drive lever in its place, making sure that its ends are correctly positioned on the end of the valve stem and the surface of the hydraulic compensator. Carefully remove the device.
2. Proceed in a similar manner to service the remaining valve drive components.
Carrying out work without using the Opel KM-565 device
Removal
1. The inability to use a special device leads to the need to dismantle the camshaft assembly with the timing mechanism housing in order to provide access to the components to be serviced.
2. After removing the valve timing case, prepare 8 clean plastic bags or plastic cups, marking them in the order of the valve numbers (you can also use a large box divided into eight separate sections). Remove the valve drive levers, oil seals and hydraulic compensators one by one and place them in appropriately marked containers.
Installing the valve drive levers in an arbitrary order will result in a violation of the correspondence between the shape and degree of their wear and the wear of the working surfaces of the camshaft cams!
Examination
1. Check the surfaces of the valve drive levers that contact the cams for signs of wear and mechanical damage - replace defective levers. If defects are found in the levers, also check the condition of the working surfaces of the corresponding camshaft cams - they will most likely also be damaged or worn out.
[Article posted on an online resource: opelbook]
2. Check the condition of the oil deflector caps and make any necessary replacements.
3. If there is no certainty in determining the condition of the hydraulic compensators, they should also be replaced - checking the correct functioning of the compensators is not possible.
Installation
1. Lubricate the hydraulic compensators and the walls of their mounting seats with clean engine oil. Install the compensators in their original places.
2. Install the oil deflector caps on the valves.
3. Lubricate the valve drive levers with clean engine oil and install them in their original places, checking the correct fit on the compensators and valve stems.
4. Finally, install the timing case with the camshaft inserted into it (see Removal and installation the cylinder head).
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