The KM and MKM numbers are Vauxhall (GM) special tool numbers. The descriptions below are taken from the wording of the factory manual (TIS) steps in our guides, so where a tool is only named in a step, that is all we can say about it. Owners managed without many of them, but the guides only say so for a few, and we mark those. Check the TIS step for your job.
Engine support and removal
| Tool | What the TIS step or owner says it is used for |
|---|---|
| KM-904 with KM-6054 | Engine support. In the NA removal steps KM-904 is attached with KM-6054 and set up on a hydraulic hoist. The Turbo removal and timing belt guides list both. Engine removal and installation (NA), (Turbo) |
| KM-6054-4 | Attached to the cylinder block during NA engine removal (the steps say to align and secure the spigots, starting at the front right). |
| KM-6042 | Used to disconnect the gearshift cables in the NA removal steps. |
| KM-796-A | Used to disconnect the fuel lines in the NA removal steps. |
| KM-J-34730-91 (listed without the second hyphen in the Turbo guide) | Fuel pressure test equipment. The steps fit it to the pressure relief valve to bleed the pressure from the fuel rail into a collecting container. |
| KM-412 with adapters KM-412-27 and KM-412-8-A | Engine overhaul (assembly) stand. The steps attach the engine to it using the adapters KM-412-27 on the exhaust and intake sides (NA) and KM-412-8-A (Turbo), and say two technicians are required. Balancer shafts (NA), Crankshaft (Turbo), Gearbox removal with the engine out |
Timing, crankshaft and flywheel
| Tool | What the TIS step or owner says it is used for |
|---|---|
| KM-6148 | Cam locking tool. The NA steps attach it to hold the cams at TDC (fitted with its positioning bolts) while the chain work is done. Camshafts and sprockets (NA), NA timing chain |
| KM-6077 | Balancer chain tensioner lock. Inserted into the designated bores after pressing in the tensioner piston. |
| KM-6105 | Crank oil seal installer (NA), with a protective sleeve that slides onto the connecting rod journal. |
| KM-J-42067 and KM-J-4206 | NA rear crankshaft oil seal. The steps slide the seal onto KM-J-42067, attach it, and press the seal in with KM-J-4206. Crankshaft seals and pickup (NA) |
| KM-J-38122-A (with KM-956-1) | Holding adapter that holds the crank pulley (rotational vibration damper) while its bolt is loosened or tightened. |
| KM-6151 | Belt tensioner tool (named in the NA timing chain guide). |
| KM-652 | Immobilises the flywheel through the starter ring gear. Flywheel removal and refitting |
| KM-853 | Camshaft locking tool for the Turbo timing belt. The steps lock the camshafts in position, release the belt tension and fit the tool again after rotating the crankshaft two turns. Camshafts, pulleys, oil seal and sensor (Turbo), Timing belt tensioner (Turbo) |
| KM-662-C | Counter-holds the crankshaft sprocket (Turbo) while its bolt is undone or tightened. |
| KM-635 | Seal ring installer, used to fit the seal ring to the Turbo crankshaft. |
| KM-693 | Assembly sleeve used when fitting the new Turbo crankshaft oil seal. Crankshaft seals, pulley, sprocket and pulse sensor (Turbo) |
| KM-949 | Screw measuring device for the balancer shaft backlash check (Turbo), used with a dial gauge set to zero. Balancer shaft unit and backlash (Turbo) |
What owners said. The NA timing chain guide lists KM-6148, KM-6077, KM-6105, KM-904 with KM-6054 and KM-6151 and says owners manage without most of them. It does not say which ones they could not do without.
Cylinder head measurements
| Tool | What the TIS step or owner says it is used for |
|---|---|
| KM-419 (OHC I), KM-512 (OHC II) | Caliper gauge and distance gauge for the valve installation height check (NA). Valves, installation height and head flatness (NA) |
| KM-301 with MKM-571-B | Measuring bridge and dial gauge for the valve indentation. MKM-571-B is also the dial gauge used for the NA crankshaft end float check in Crankshaft and bearing clearances (NA). |
| KM-6215 (with KM-6215-1, -4 and -5) and MKM-6086 | Assembly tool set (assembly device, lever and side mounts) and the installation/removal set used for fitting valves in the NA cylinder head. |
Oil filter housing, water pump and cooling
| Tool | What the TIS step or owner says it is used for |
|---|---|
| KM-6150 | Oil filter wrench for the top cover. The oil change guide says it is little more than a 32 mm socket, and that a copy sold as the Laser 6037 is the same thing. Oil and filter change |
| KM-6264 | Remover/installer for the securing ring of the oil cooler adaptor (fitted to 120 Nm). Owners who didn't have it used a borrowed one, a homemade ring or a ring spanner. Oil filter housing leaks, seals and tool |
| KM-6416 | Holding wrench to counter-hold the adaptor if its securing ring loosens while you take the top cover off. |
| KM-J-43651 | Water pump sprocket locking tool (the TIS number). Owners quoted about £40 to £80 in 2010 for a copy, also sold as a Laser-branded tool. Water pump replacement |
| KM-471 | Applies 1.0 to 1.5 bar to the cooling system in the Vauxhall bleed method. One owner found it expensive and built his own. Coolant change and bleeding |
Gearbox and driveshafts
These are named in the F23 gearbox overhaul steps. Most are bearing, gear and cover drifts and presses. The descriptions are the TIS wording of each step. See F23 gearbox overhaul: shafts and bearings, Gear shift linkage adjustment and shift mechanism and Driveshaft gaiter replacement and overhaul.
| Tool | What the TIS step or owner says it is used for |
|---|---|
| KM-6115 on KM-113-2 | The steps install KM-6115 to the gearbox, then onto KM-113-2 for the overhaul, and remove it afterwards. Also named in the shift mechanism guide. |
| KM-248 | Used to drive the intermediate shaft bearing out of the clutch housing. |
| KM-248-2 and KM-248-4 | Used to remove the drive shaft bearing and spacer sleeve from the clutch housing. |
| KM-6119, KM-6120 and KM-6112 (each with KM-523-1) | Install the intermediate shaft bearing (KM-6119), the drive shaft bearing (KM-6120) and the spacer sleeve (KM-6112) into the clutch housing. |
| KM-6122 and KM-6123 (with KM-523-1) | Remove and install the main shaft bearings (KM-6122), and remove the drive shaft bearing from the transmission housing (KM-6123). |
| KM-6101 with KM-328-B, and KM-6102 with KM-523-1 | Drive the intermediate shaft cover flush: KM-6101 with KM-328-B into the cover, KM-6102 with KM-523-1 into the transmission. |
| KM-514 | Presses 3rd gear onto the main shaft. |
| KM-6219 | Presses 4th gear onto the main shaft, and presses a bushing onto the drive shaft in the gaiter guide steps. |
| KM-6220 with KM-6223-1, KM-6223-2 or KM-6224 | Presses 4th gear (KM-6223-1 and KM-6223-2) and 3rd gear (KM-6223-1 and KM-6224) off the main shaft. |
| KM-6220 with KM-6221 or KM-6222 | KM-6221 removes the 5th/reverse gear synchromesh and bushing from the main shaft. KM-6222 removes the thrust washer, needle bearing and 3rd gear from the drive shaft. |
| KM-6126 and KM-6223 (with KM-523-1) | Press the intermediate shaft out of the 1st/2nd gear synchromesh body. |
| KM-621-23 | Positioned on the transmission housing to determine the dimension from the bearing inner ring to the housing. |
Special tools that are not KM numbers
- Hard top tool. The tool supplied with the hard top is needed for the tethered brackets and covers, and the workshop procedure warns that any other tool may damage parts. See Hard top fitting.
- OP-COM or similar. A tool that can read the immobiliser and the car's security code. See Immobiliser: engine starts then stops.
- Ball joint and bush tool. Sold by Elise Parts, or a vice and a threaded bar. See Wishbone ball joints and bushes.
- Bearing puller, press and hub puller. Named in the limited slip differential and wheel hub guides: Fitting a limited slip differential and Wheel hub and bearing replacement.
- Pipe cutter and flaring tool. For hard brake pipe jobs. See Brake pipes in the sill.
Help wanted
We don't have photos or sizes for the special tools, or owners' homemade alternatives for most of them. If you made or borrowed a substitute for a KM tool, please tell us which one and how well it worked.