Removal and installation the cylinder head (Opel Astra H)

Caution: Cylinder head removal operations should only be performed on a cold engine (ambient temperature) engine!

Note: This section provides a detailed description of the procedure for removing the engine head only for engines of earlier releases and those most widely represented on models supplied to the Russian market. However, sufficiently experienced auto mechanics will be able to independently remove the cylinder head on other models using the materials of this and some other sections of this Chapter!

Z16XEP Engine

1. Disconnect the cable from the negative terminal of the battery.

2. Remove the air cleaner (see Chapter 4).

3. Remove the ignition module (see Chapter 1, Section 22).

4. Remove the multi-rib belt (see Section 7).

5. Raise the car on a lift, drain the coolant (see Chapter 3) and remove the right engine boot (see Section 5).

6. Disconnect the lambda probe cable channels (see accompanying illustration).



7. Disconnect the exhaust system section from the catalytic converter (see accompanying illustration).





8. Remove the intake manifold support from the engine block (see accompanying illustration) and remove the vacuum hose. Disconnect the electrical wiring from the fuel tank vent valve.



9. Remove the hose from the fuel tank vent valve by squeezing the retaining ring by the ribbed surfaces (see accompanying illustration).



10. Release the pressure in the fuel system through the service nipple using a special tool KM-J-34730-91 (see accompanying illustration).





11. Disconnect the fuel line from the fuel distribution line using the KM-796-A tool (see accompanying illustration).



12. Disconnect the cooling system pipes from the throttle body and from the interior heater - to disconnect the quick-release couplings, move the retaining rings back as far as they will go (see accompanying illustrations).





13. Disconnect the engine management system wiring and ground bus (see accompanying illustration).





14. Disconnect the intake manifold pressure sensor cable connector (see accompanying illustration).



15. Disconnect the camshaft sensor wiring connector.

16. Disconnect the PDA vacuum unit wiring connector (see accompanying illustration).



17. Disconnect the wiring connectors of the thermostat, coolant temperature and EGR valve sensors (see accompanying illustration).





18. Disconnect the crankshaft sensor wiring connector (see accompanying illustrations).



19. Disconnect the brake booster vacuum line and the throttle control wiring connector (see illustration 11.13).

20. Disconnect the electrical wiring lines from the engine (see accompanying illustration).



21. Disconnect the crater ventilation system hose from the cylinder head.



22. Remove the upper timing belt cover (see Section 6).

23. Raise the vehicle on a lift and remove the catalytic converter mounting bracket (see accompanying illustration). Remove the crankshaft pulley (see Section 5) and then remove the timing belt (see Section 8).



24. Disconnect the lower coolant pipe from the thermostat housing (see accompanying illustration).



25. Remove the upper exhaust manifold cover (see accompanying illustration), for which disconnect the wiring of the oil pressure sensor in the engine head and unscrew the 2 mounting bolts. Remove the oil pressure sensor and the pre-catalytic lambda probe. Remove the engine lifting eye, and then, having unscrewed the 3 mounting bolts, remove the exhaust manifold protection.





26. Remove 11 mounting bolts and remove the exhaust manifold (see accompanying illustration). Then unscrew the 5 bolts securing the cooling system pipe to the engine block and remove the pipe.



27. Remove the cylinder head cover (see Section 10).

28. Loosen the cylinder head mounting bolts in the reverse order shown in Illustration 11.29 in two steps - in the first approach, loosen the bolts by 90°, and in the second - by 180°, then completely unscrew the bolts and remove the cylinder head.

29. Installation is carried out in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force (see Specifications). When installing the cylinder head, use new mounting bolts. Tightening the cylinder head mounting bolts is performed in the sequence shown in the accompanying illustration in 5 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device. The features of installing the cylinder head cover are given in Section 10.

Z18XE Engine

30. Remove the multi-rib belt (see Section 7).

31. Remove the right engine boot (see Section 5).

32. Remove the alternator mounting bolt and bracket (see accompanying illustration).



33. Remove the right front wheel (see Introduction) and drain the coolant (see Chapter 3). Disconnect the front exhaust pipe from the exhaust manifold by loosening the 3 mounting nuts.

34. Remove the exhaust tract support (see illustration 11.32) to the side, for which disconnect it from the intake manifold by unscrewing the bolt and loosening the bolt securing the support to the cylinder block.

35. Remove the multi-rib belt tensioner, remove the crankshaft pulley and install the right engine mount remover (see Section 5).

36. Disconnect the crankcase ventilation hoses from the cylinder head cover and throttle body, disconnect the cooling system line from the intake manifold and cylinder head cover, disconnect the brake booster vacuum line from the intake manifold by squeezing the clamps (see accompanying illustration). Disconnect the throttle body wiring connector.



37. Disconnect the electrical wiring cable connectors and other components as shown in the accompanying illustrations.





38. Disconnect the cable channel (wiring harness in the housing) injectors from the engine. Release the pressure in the fuel system through the service nipple using a special device KM-J-34730-91 (see illustration 11.10). Drain the fuel into a suitable container.

39. Disconnect the fuel line (see illustration 11.37b) and the pre-catalytic lambda probe wiring connector.

40. Disconnect the heater hose (see accompanying illustration), and then disconnect the cooling system line from the thermostat housing.



41. Remove the rear engine lifting eye and disconnect the intake manifold assembly by unscrewing the 7 mounting nuts (see accompanying illustration).



42. Disconnect the cooling system pipes from the water pump by removing the 2 mounting clamps (see accompanying illustration). Disconnect the upper water pipe from the thermostat housing. Unfasten the engine oil dipstick tube by unscrewing the 2 mounting bolts, loosen the tube bracket bolt and move it to the side.



43. Remove the right engine support and remove the timing belt (see Section 8).

44. Remove the timing belt drive rollers (see accompanying illustration), remove the camshaft gears (see Section 5) and remove the right engine support mounting bracket from the cylinder block.



45. Remove the head cover, unscrew the mounting bolts and remove the cylinder head - the order and sequence of unscrewing/tightening the cylinder head mounting bolts is the same as for the Z16XEP engine (see above).

46. Installation is carried out in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force (see Specifications). When installing the cylinder head, use new mounting bolts. The features of installing the cylinder head cover are given in Section 10.

Z14XEP Engine

Removal

47. Disconnect the cable from the negative terminal of the battery and remove the air cleaner (see Chapter 4).

48. Disconnect the wiring harness and cooling system lines from the throttle body (see accompanying illustration).



49. Release the pressure in the fuel system through the service nipple using a special tool KM-J-34730-91 (see accompanying illustration). Drain the fuel into a suitable container.



50. Disconnect the fuel line using the KM-796 tool and the brake booster vacuum line (see accompanying illustration).



51. Disconnect the fuel tank vent valve line from the throttle body (see illustration 11.51a) and the valve wiring connector (see illustration 11.51b).





52. Disconnect the exhaust pipe (see Chapter 4) from the catalytic converter by unscrewing 3 bolts.

54. Drain the coolant (see Chapter 3).

55. Disconnect the wiring harness cable connectors shown in the accompanying illustration.



56. Disconnect the thermostat housing from the water pump by unscrewing 3 bolts and disconnect the cooling system pipe from the radiator (see accompanying illustration).



57. Disconnect the cooling system pipe from the EGR valve (see accompanying illustration).



58. Disconnect the engine oil dipstick tube from the exhaust manifold guard by unscrewing the mounting bolt and remove the tube.

59. Remove the exhaust manifold protection, for which you must first disconnect the pre-catalytic lambda probe wiring and the lifting eyes (see accompanying illustration).



60. Disconnect the exhaust manifold by loosening the 9 mounting nuts.

61. Remove the oil filter by first detaching the filter cover and removing the filter element (see Chapter 1, Section 6), and then remove the oil filter housing (see accompanying illustration).



62. Remove the multi-rib belt (see Section 7).

63. Remove the water pump pulley by unscrewing the 3 mounting bolts.

64. Remove the mounting bolts that secure the power plant attachments to the cylinder head (see accompanying illustration).



65. Disconnect the crankcase ventilation hoses from the cylinder head cover and remove the ignition module (see Chapter 1, Section 22).

66. Remove the 13 mounting bolts and remove the cylinder head cover.

67. Bring the piston of the first cylinder to the TDC position of the end of the compression stroke (see Section 6).

68. Remove the camshaft drive sprockets (see Section 8) and place them together with the chain in the timing drive housing.

69. Loosen the head mounting bolts in the reverse order to that shown in the accompanying illustration in 2 steps - in the first approach, loosen the bolts by 90°, and in the second - by 180°, then completely unscrew the bolts.



70. Using an assistant, remove the cylinder head - the chain tensioner should move along its guide. The removed head should be placed on a wooden surface.

71. Remove any remaining sealant from the surfaces on the inside of the rear timing cover and the top surface of the cylinder block, carefully pry up the gaskets at the points indicated by arrows in the accompanying illustration and remove them.



Installation

72. Install new gaskets and trim the protruding edges (I) on the timing belt cover side (see accompanying illustration).



73. Apply a bead of sealant before installing a new head gasket (gray color) approximately 2 mm thick at the corners of the junction of the cylinder block with the timing belt housing (see accompanying illustration).

Attention: Installation of the head must be completed no later than 10 minutes after applying the sealant!

Install a new cylinder head gasket with the "TOP" marking facing up and press it into place where the sealant was applied. Insert the timing belt cover mounting bolts (see ibid), place the gaskets of the vertical surface of the timing belt casing on them and press the gaskets at the bottom, in the places where the sealant is applied.

74. Using the help of an assistant, install the cylinder head - place the chain tensioner on the guide and using the KM-955-1 device (see illustration 8.71) fix it.

75. Secure the cylinder head by tightening the new head mounting bolts a few turns, tap the head using a rubber mallet in the direction of the timing belt cover and tighten the 3 timing belt cover mounting bolts (see accompanying illustration).



76. Tightening of the cylinder head mounting bolts is performed in the sequence shown in Illustration 11.69, in 4 steps (see Specifications): on the first approach, tighten the bolts using a torque wrench, and on subsequent approaches, using a special angle measuring device.

77. Remove the 3 previously installed timing cover mounting bolts, install and tighten the removed water pump mounting bolts, and then all timing cover mounting bolts.

78. The installation of the remaining components is carried out in the reverse order of removal, replacing all the sealing gaskets of the removed components. After installing the drive sprockets, adjust the valve timing (see Section 6). The features of installing the cylinder head cover are given there.

Engines Z20LE(L/R/H)

79. Disconnect the cable from the negative terminal of the battery and remove the air cleaner with air ducts (see Chapter 4).

80. Remove the multi-rib belt (see Section 7).

81. Remove the ignition module (see Chapter 1, Section 22).

82. Disconnect the mounting bracket from the intake manifold and generator and the mounting bracket from the generator, intake manifold and cooling flange (see accompanying illustration). Move the generator back.



83. Raise the car, remove the right front wheel (see Introduction), drain the coolant (see Chapter 3).

84. Disconnect the vacuum reservoir bracket from the intake manifold and remove the front exhaust pipe.

85. Remove the right engine boot (see Section 5) and multi-ribbed belt (see Section 7). Loosen the mounting bolts and remove the multi-rib belt tension roller.

86. Remove the crankshaft pulley and install the right engine mount remover (see Section 5).

Article posted on an online resource: opelbook.ru

87. Disconnect all lines from the throttle body (see accompanying illustration) and remove the throttle body.



88. Disconnect the brake booster vacuum line from the intake manifold.

89. Release the pressure in the fuel system through the service nipple using a special tool KM-J-34730-91 (see Chapter 4). Drain the fuel into a suitable container.

90. Disconnect the fuel lines and cooling system hoses shown in the accompanying illustration.



91. Remove the upper timing belt cover, disconnect the interior heater hoses and all injector cable channel connectors (see accompanying illustration). Disconnect the cable channel from the injectors and set it aside.



92. Remove the timing belt (see Section 8).

93. Remove the camshafts (see Section 10).

94. Unscrew the mounting bolts of the rear timing cover from the cylinder head (see accompanying illustration).



95. Using the KM-2355 device, loosen the cylinder head mounting bolts one by one in several approaches in the reverse order shown in Illustration 11.95, loosening the bolts by 1-0.5 turns per approach, then completely unscrew the bolts and remove the cylinder head.



96. Installation is carried out in the reverse order of removal, replacing all sealing gaskets of the removed components - do not forget to clean the surfaces before installation. The new head gasket should be installed with the "TOP" marking facing up. Tighten the threaded connections to the required force (see Specifications). When installing the cylinder head, use new mounting bolts. Tightening the cylinder head mounting bolts is performed in the sequence shown in Illustration 11.95 in 5 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device. The features of installing the cylinder head cover are given in Section 10.

Engine Z22YH

97. Tightening of the cylinder head mounting bolts is performed in the sequence indicated in the accompanying illustration from 1 to 10 in 4 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, using a special angle measuring device (see Specifications). New bolts must be used.



98. Insert 4 bolts into the timing case, having previously lubricated their threads with a locking compound, and tighten in sequence from 11 to 14 with a force of 35 Nm.

Note: Before installing the bolts, carefully clean the threads of the holes from any remaining old compound.

Z17DTL/H Engines

Removal

99. The following describes the operations for removing the engine cylinder head on models equipped with a crankcase ventilation system.

100. Before performing work, it is necessary to disconnect the battery and remove the refrigerant from the air conditioning system using special service equipment (contact the Opel company service station) and first drain the coolant (see Chapter 3).

101. Remove the engine cover (see Section 2), remove the air cleaner (see Chapter 4) remove the multi-rib belt (see Section 7), remove the engine crankcase protection (see Section 5), drain the engine oil from the crankcase (see Chapter 1, Section 6).

102. Remove the air conditioning system compressor and timing case (see Section 10), while completing all the work on removing the toothed belt (see Section 8) and injectors (see Chapter 4).

103. Disconnect the lower cooling system line from the exhaust gas recirculation (EGR)heat exchanger (see accompanying illustration).



104. Disconnect the front end of the exhaust pipe from the front catalytic converter by unscrewing the 3 mounting bolts (see accompanying illustration).



105. After removing 2 bolts, disconnect the engine oil dipstick tube from the top of the oil pan by removing 2 bolts.

106. Disconnect the oil return line from the turbocharger (see accompanying illustration).



107. Disconnect the turbocharger oil feed line from the engine block (see accompanying illustration).



108. Remove the EGR system heat exchanger (see accompanying illustration).



109. Disconnect the wiring connector from the EGR system regulator, disconnect the cooling system pipe from the EGR recirculator housing and remove the housing (see accompanying illustrations).

Note: The housing mounting bolts are of different lengths - remember or mark their installation locations.

110. Disconnect the vacuum hose from the turbocharger control sensor (see accompanying illustration).



111. Remove the exhaust manifold guard by unscrewing 4 bolts (see accompanying illustration).



112. Disconnect the oil feed line from the turbocharger housing (see accompanying illustration).



113. Remove the exhaust manifold together with the turbocharger (see accompanying illustration), having unscrewed 2 bolts and 7 fastening nuts.



114. Remove 16 cup tappets from the head (see accompanying illustration) - remember the order of their installation during assembly; they must be exactly in their places.



115. Unscrew the cylinder head mounting bolts one by one in several steps, loosening them by 1-0.5 turns per approach, in the order shown in the accompanying illustration. Remove the head.



Examination

116. After removing the head, it is necessary to clean the mating surfaces of the head and engine block and check them for surface deformation using a device with a flat straight edge (see accompanying illustration).



117. The thickness of the new cylinder head gasket is of particular importance for this engine. To obtain the optimum combustion chamber volume, the engine pistons protrude slightly on the block surface at their TDC. To prevent the piston and the timing valves from touching during operation, it is necessary to provide the appropriate clearance.

118. To measure the height of the piston protrusion above the block surface, it is necessary to install devices on the block surface (see accompanying illustration) and set "O" on the plunger-type meter scale at the moment when the meter probe touches the block surface.



119. Measure the protrusion height of all pistons one by one, taking measurements at two points on each piston (see accompanying illustration) — for measurement it is necessary to select points (1) and (2) or another pair — (3) and (4). During measurement it is necessary to smoothly rotate the crankshaft to determine the highest point of piston lift. After finishing the measurements, rotate the crankshaft 60° counterclockwise.



120. Determine the thickness of the new gasket according to the data in the table (see Specifications). The corresponding markings (holes) are applied to the gaskets (see accompanying illustration).



Installation

121. Installation is carried out in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force (see Specifications). Tightening of the cylinder head mounting bolts is performed in 3 stages: during the first approach, tighten the bolts using a torque wrench, and during subsequent ones, using a special angle measuring device. When installing the cylinder head, use new mounting bolts. The tightening order of the bolts is the same as for the Z14XEP engine (see illustration 11.69).

Note: Only 1 to 10. Adjust the valve timing (see Section 9).

Z13DTH Engine

122. Tightening of the cylinder head mounting bolts is performed in the sequence indicated in the accompanying illustration from 1 to 10, in 3 steps (see Specifications): tighten the bolts using a torque wrench the first time and a special angle measuring device the next time. New bolts must be used.

Z19DT(H) Engines

123. Tightening of the cylinder head mounting bolts is performed in the sequence shown in the accompanying illustration in 5 steps (see Specifications): for the first and second approaches, tighten the bolts using a torque wrench, and for subsequent approaches, use a special angle measuring device.

Note: Illustration shows Z19DTH engine.