Engines 1.0 and 1.2 l
Removal
1. Loosen the mounting bolts and remove the protective cover (2) of the cylinder head cover in the direction indicated by the arrow in the illustration.
Removing the protective cover
2. Disconnect the wiring harness connector (4), disconnect the PCV hoses (1) from the cylinder head cover and disconnect the ignition module wiring harness multi-pin connector (3) (refer to illustration).
3. Remove the ignition module mounting bolts.
4. Remove the ignition module upwards from the cylinder head. To do this, screw the special KM-574 grip (1) into the module. If there is no grip, screw in the corresponding bolts and pull out the ignition module by the bolts. Remove the oil filler cap (2).
Removal the ignition module and oil filler cap
5. Unscrew the cylinder head cover mounting bolts evenly and in several steps.
Cylinder head cover mounting bolts
6. On the engine DOHC 1.2L the cylinder head cover is additionally secured with four bolts.
7. Remove the cylinder head cover.
8. Remove the cylinder head cover gasket and clean the mating surfaces.
Installation
1. Insert a new seal into the cylinder head cover.
2. Apply sealant to the mating surfaces.
Places to apply sealant
3. Install the cylinder head cover with a new seal and tighten the mounting bolts evenly in several steps 8 Nm.
4. Install the oil filler cap.
5. Install the ignition module onto the spark plugs and tighten its mounting bolts with force 8 Nm.
6. Further installation is carried out in the reverse order of dismantling the components.
Engines 1.4 and 1.6 l
Removal
1. Release the fuel pressure (see Chapter Fuel, exhaust and emission control systems).
2. Disconnect the negative cable from the battery.
3. Remove the air filter with the MAF sensor and air intake sleeve (see Chapter Fuel, exhaust and emission control systems).
4. Drain the coolant into a previously prepared container (see Chapter Engine cooling, interior heating and air conditioning systems).
5. Disconnect the upper and lower radiator hoses (see Chapter Engine cooling, interior heating and air conditioning systems).
6. Unscrew the mounting bolts and remove the tank from the engine compartment bulkhead.
7. Remove the high voltage wire cover.
8. Disconnect the fuel supply hose (1) from the fuel line and the fuel return hose (2) from the fuel pressure regulator. Mark the fuel hoses with tape beforehand to avoid confusion during installation. Clamp the hoses.
Fuel hoses
Place a rag under any leaking fuel.
9. Disconnect the PCV hose (1) and brake booster vacuum hose (2) from the top of the intake manifold.
PCV hose and brake booster hose
10. Disconnect the vacuum hose from the fuel pressure regulator (1) and from the evaporator check valve (2) on the top of the intake manifold. The accompanying illustration shows the C16XE engine. On other engines, additionally disconnect the manifold pressure (MAP) sensor vacuum hose.
Fuel Pressure Regulator and Intake Manifold Vacuum Hoses
11. On c16XE engine loosen the clamp (1) of the evaporator check valve (arrow) with a screwdriver and remove it together with the valve upwards from the holder. Move the evaporator check valve to the side.
Removal the evaporator check valve
12. Remove the throttle cable from the throttle body and set the cable aside (see Chapter Fuel, exhaust and emission control systems).
13. Disconnect the DIS ignition module multi-pin connector and disconnect the wiring from the temperature sensor on the thermostat housing.
14. Disconnect the air injection pipe from the throttle valve branch.
15. Remove the throttle valve pipe mounting bolts (arrow). Remove the pipe and set it aside.
Throttle body mounting bolts
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16. Remove the bolts securing the upper part of the intake manifold.
Upper intake manifold mounting bolts
17. Disconnect the CKP sensor (2) and the CMP sensor (3) connector c16XE engine disconnect the injector connector (1).
Sensor and injector connectors
18. Disconnect the negative cable from the bottom of the intake manifold.
19. Disconnect the vacuum hose from the fuel pressure regulator.
20. Disconnect the PCV hose from the cylinder head cover.
21. On x14XE and X16XE engines remove the auxiliary air supply pump from the engine together with the electrical wiring (see Chapter Fuel, exhaust and emission control systems).
22. Loosen the 10 timing belt cover mounting bolts and remove the cover together with the sealing elements.
Installation
1. Make sure the mating surfaces of the cover and head are clean and dry.
2. Install new gaskets (1) and new sealing rings (2) on the cylinder head.
Timing Belt Cover Sealing Elements
To prevent the sealing rings from falling into the cylinder head during installation, lubricate them with a small amount of Vaseline. Lubricate the corners of the camshaft bearing cover on the camshaft pulley side with OPEL L000 0295 sealant.
3. Carefully place the timing belt cover in its regular place, checking the correct placement of the seals. Screw in the mounting bolts and, moving in a spiral from the center to the edges, tighten them evenly with force 8 Nm.
4. Install the upper part of the intake manifold and tighten its mounting bolts with force 8 Nm.
5. Install the throttle body pipe with a new sealing gasket and tighten the bolts securing it to the top of the intake manifold with force 8 Nm.
6. Install the throttle cable onto the throttle body and check its adjustment (see Chapter Fuel, exhaust and emission control systems).
7. Further installation is carried out in the reverse order of dismantling the components.
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