Start work only after the engine has completely cooled down!
Removing
1. Disconnect and remove the battery (see chapter Engine Electrical Systems).
2. Empty the cooling system (see chapter Engine cooling, interior heating and air conditioning systems).
3. Turn out the spark plugs and remove the accessory drive belt (see chapter Vehicle settings and routine maintenance).
4. Remove the timing belt (see Section Removing and installing timing belt).
Cylinder Head Assembly Components
1 - Camshaft bed cover
2 — Bolt, tightening force: 8 Nm
3 - Sealing gasket
4 - Camshaft seal. To remove, turn the washer and use pliers to remove the bolt together with the O-ring.
5 — a gear wheel of a camshaft
6 - Washer
7 - Bolt, tightening torque: 45 Nm; necessarily replaced
8 - Rocker
9 - Hydraulic compensator
10 - Pressure element
11 - Rusks
12 — the Top plate of a spring
13 - Spring
14 - Oil deflector cap
15 - Lower spring plate
Exhaust valve: rotary valve device
Inlet valve: spring seat
16 - Sealing gasket of the cylinder head
17 - Valve
18 - Cylinder head
19 - Bolt, tightening torque: 8 Nm
20 - Limiting plate
21 - Camshaft
22 - Washer
23 — Bolt of fastening of a head of cylinders
24 - Camshaft bed
5. Remove the intake piping and exhaust manifold (see chapter Power supply systems, release and reduction of toxicity of exhaust gases). If the cylinder head is not serviceable, it can be removed complete with pipeline and manifold:
- Tape and disconnect all wiring to the cylinder head, intake manifold and throttle body;
- Relieve pressure in the fuel system and disconnect the fuel lines from the fuel line. Disconnect also all vacuum hoses and hoses of system of cooling from the inlet pipeline/throttle case;
- Remove the support bracket from the intake manifold, also remove the upper alternator mounting bracket;
- Disconnect the accelerator cable;
- Disconnect from a final collector a reception pipe of system of release of the fulfilled gases in gathering with a basic arm;
- Disconnect the electrical wiring from the lambda probe.
6. Remove the timing cover (see Section Removal and installation of a cover of the gas-distributing mechanism).
7. Remove the camshaft gear (see Section Removal and installation of timing gears).
8. Turn out bolts of fastening of a back cover of a drive of GRM to the case of the timing mechanism.
9. On C14NZ engine Disconnect the wiring connectors and BB cables from the ignition distributor. On engines X12SZ and C14SE Disconnect the wiring connectors at the DIS ignition module. Loosen the ground bus mounting bolt at the front of the head and remove the electrical wiring protection cover from the head.
10. Release fixing collars and disconnect hoses of system of cooling from a thermostat casing.
11. Make sure that all hoses, tubes, wires and other communication lines are disconnected and do not interfere with the dismantling of the cylinder head.
12. Operating in the reverse order shown in the illustration, gradually, a quarter of a turn at a time, loosen the cylinder head bolts so that they can be turned out manually. Remove the head bolts complete with your washers.
13. Lifting up, separate the body of the gas distribution mechanism from the head, - if necessary, tap the body from the sides with a soft-faced hammer.
In no case do not pry the case with a lever in order to avoid damage to the mating surfaces!
16. Mark the position of the two guide bushings, remove them from the head and put them in a safe place.
17. Separate the cylinder head from the block - try not to drop the valve drive levers and oil seals. If necessary, lightly tap the head from the sides with a soft-faced hammer - in no case DO NOT Pry it with a lever! Mark the position of the two guide bushings, remove them and put them in a safe place.
18. Remove the gasket - do not discard the gasket yet to identify a new one.
Preparing for installation
1. Thoroughly clean and dry the mating surfaces of the head and cylinder block. Use a hard plastic or wood scraper to remove all traces of old gasket material and carbon deposits. Also clean the piston bottoms. Be extremely careful - surfaces are easily damaged. Remember that dirt should not get into the oil channels, water galleries, channels and threaded holes - plug them with plugs or seal them with tape. To prevent deposits from getting into the gaps between the pistons and cylinders, fill the last with a thick lubricant, which, after cleaning, can be easily removed with a stiff brush. After cleaning, wipe all surfaces with a clean, dry cloth.
2. Inspect the mating surfaces of the head and block for deep scratches, cracks, or other damage. Minor defects can be eliminated with a small scraper, in more serious cases, the head should be machined or replaced.
3. Make sure the threaded holes are clean and dry - just in case, blow them out with compressed air (you can use a bicycle pump). The presence of traces of grease in the blind holes can lead to the destruction of the block when the bolts are tightened as a result of the increase in hydraulic pressure.
4. Head bolts must be replaced without fail, regardless of their current condition.
5. Using a steel ruler and a blade-type feeler gauge, check the flatness of the mating surface of the head (see part General and overhaul of the engine).
6. Replace the cylinder head bolts - the bolts must be replaced without fail, regardless of their current condition.
Installation
1. Bring the piston of the first cylinder to the TDC position of the end of the compression stroke.
2. Wipe dry the mating surfaces of the block and head with a clean rag.
3. Make sure both guide bushings are in place. Lay a new sealing gasket on the mating surface of the cylinder block, - the gasket is placed with a mark «OBEN/TOP» up.
Correct position of the cylinder head gasket
4. Install the head on the cylinder block - make sure that the guide bushings fit into the receiving sockets.
5. Dry the mating surfaces of the head and timing case with a clean rag. Make sure that the valve levers, oil seals and hydraulic compensators are installed correctly.
6. Apply a layer of sealant OPEL ET-No. 15 03 166 to the upper mating surface of the cylinder head.
Applying sealant to the surface of the head mating with the timing case
7. Install the guide bushings and lubricate the valve levers with clean engine oil.
8. Carefully install the timing case with the camshaft inserted into it onto the cylinder head, make sure that the guide bushings get into the receiving sockets correctly, - make sure that the guide bushings get into the receiving sockets correctly.
9. Install the washers on the NEW cylinder head bolts, then screw in the bolts and hand-tighten.
10. Working in a strictly defined sequence, evenly tighten the bolts in accordance with the requirements of the specification.
Cylinder Head Bolt Tightening Order
11. Screw in the bolts of the rear timing cover and tighten them with the required force.
12. Install the camshaft gear (see Section Removal and installation of timing gears) and timing belt (see Section Removing and installing timing belt).
13. Restore the original wiring connection, make sure that the harnesses are routed correctly and that they are securely fastened in all provided intermediate clamps.
14. Connect the hoses of the cooling path to the thermostat housing - make sure the fastening clamps are tightened securely.
15. Reinstall intake manifold and exhaust manifold (see chapter Power supply systems, release and reduction of toxicity of exhaust gases).
16. Reinstall the crankcase guard and right front wheel. Lower the vehicle to the ground and tighten the wheel bolts to the correct torque.
17. Make sure that all hoses are connected correctly and securely, then charge the cooling system (see chapter Engine cooling, interior heating and air conditioning systems).
18. Connect the battery.
19. Start the engine and check it for signs of developing fluid leaks.
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