Removal and installation the cylinder head (1.4-1.6 l engine) (Opel Corsa C)

Note: Before the inspection procedure, warm up the engine to operating temperature (oil temperature – 80°C).

Removal

Open the hood

Remove the air filter housing.



Disconnect the mass air flow sensor wiring harness.

Disconnect the fuel tank vent line.

Disconnect the engine ventilation hose from the air intake hose.

After removing the clamp, disconnect the air intake hose from the throttle body.

After removing the clamp, disconnect the air filter housing.

Loosen the lower rubber support mounting bolt and remove it.

Disconnect the intake pipe.

Disconnect the throttle body wire harness connectors.

Disconnect the coolant hoses from the throttle body.



Place a drain container underneath.



Remove 2 clamps.

Disconnect the coolant hose.

Relieve the fuel pressure using the special tool KM-J-34730-91 through the test nipple, to do this, unscrew the protective cap of the test nipple.

Collect escaping fuel in a suitable container.

Follow safety rules and local laws

Disconnect the fuel supply line from the fuel rail using the special tool KM 796.

Disconnect the quick release coupling.

Disconnect the brake booster vacuum line from the intake manifold.

Disconnect the quick release coupling.

Disconnect the fuel tank vent valve line from the intake manifold.

Disconnect the fuel tank vent valve harness connector.

Disconnect the front exhaust pipe from the catalytic converter by unscrewing the 3 mounting nuts.





Place a drain container underneath



Attach a suitable hose to the drain fitting.

Loosen the coolant drain screw.



Drain the coolant.

Tighten the coolant drain screw.

Disabling electrical power and engine control systems

Disconnect the engine control module wiring harness connectors.

Disconnect the fuse.

Disconnect the 2 ground wires by unscrewing the 2 mounting nuts.

Disconnect the 6 engine wiring harness plugs: plug, ignition module, oil pressure sensor, coolant temperature sensor, camshaft sensor.

Release the wiring harness.



Disconnect the thermostat housing from the coolant pump by unscrewing the 3 mounting bolts.



Remove the gasket.

Disconnect the coolant hose from the radiator.

Disconnect the coolant hose from the EGR valve.



Loosen the clamp.

Disconnect the oxygen sensor wiring harness connector.

Remove the bracket plug.

Disconnect the wiring harness from the bracket.

Remove the engine lifting brackets by unscrewing the 2 mounting bolts.

Remove the heat shield.

Unscrew 2 bolts.

Remove the oil dipstick guide tube.

Disconnect from the exhaust manifold.



Loosen the bolt.

Remove the exhaust manifold by unscrewing the 9 mounting bolts.

Removal the oil filter

Remove the cover from the oil filter housing.

Remove the oil filter element.

Disconnect the oil filter housing from the cylinder block by unscrewing the 3 mounting bolts.

Remove the gasket.

Remove the poly V-belt.

Mark the direction of rotation.

Turn the poly V-belt tensioner clockwise using the KM 6131 tool.

Install fixture KM-955-2.

Loosen the poly V-belt tensioner.

Disconnect the coolant pump belt pulley from the coolant pump by unscrewing the 3 mounting bolts.

Remove the timing case.

Remove 4 bolts securing the coolant pump.

Unscrew the 5 bolts securing the valve timing housing.

Disconnect the camshaft sensor from the valve timing housing by unscrewing the mounting bolt.

Disconnect the engine ventilation hose from the cylinder head cover.

Removal the ignition module

Remove the ignition module wiring harness.

Remove the ignition module cover from the cylinder head cover in the direction of the arrow

Unscrew the two mounting bolts.

Separate the ignition module from the spark plugs using the special tool KM 6009.

Disconnect the cylinder head cover from the cylinder head by unscrewing the 13 mounting bolts.



Remove the cylinder block base plug.

Lower the car.

Set the piston of the first cylinder to the TDC position (ignition)

Install the special tool KM 952. Smoothly rotate the crankshaft until the special tool KM 952 reaches the stop.

The mark on the crankshaft pulley must align with the protrusion on the timing mechanism housing.

Remove the guide from the cylinder head by unscrewing the 2 mounting bolts.

Remove the camshaft gears by unscrewing the 2 mounting bolts.

Hold the camshaft hex with an open-end wrench.

Place the camshaft sprockets on the same side as the chain in the timing case.

Removal the cylinder head

Loosen the cylinder head mounting bolts in the order shown in the figure.

Loosen 12 bolts by 90°.

Loosen 12 bolts 180°.

Remove the cylinder head

Place the chain tensioner behind the tension bar.

Install the cylinder head on blocks.

Remove the cylinder head gasket.

Disconnect the timing case gasket.

Cut the elastomer sealing lips (size II) of the timing case gasket from the inside to the outside with a sharp knife and make them flush with the cylinder block



Carefully bend the gasket at the bend points (arrows).



Remove any remaining gasket and clean the sealing surfaces

Note: Ensure that any remaining elastomer sealing lip is removed from the space between the timing case and the cylinder block and from the timing case.

Check the cylinder head and cylinder block for flatness.

When checking or repairing the cylinder head, disconnect all external components from the cylinder.

Original article on the web portal [OpelBook.ru]



Install the cylinder head gasket.

Cut off the protruding parts of the elastomer (dimension I) on the valve timing mechanism side.

Installation

Apply a bead of silicone sealant (grey) to the timing case/cylinder block approximately 2 mm thick (dimension I).

Note: The cylinder head must be installed within 10 minutes after applying the silicon (gray) sealant and installing the timing case bolts.

Install a new cylinder head gasket onto the cylinder block.





The TOP marking must be on top.

Press the gasket in the area where the silicon (gray) sealant will be applied.

Install the upper timing case gasket.



Install 2 (arrows) timing case bolts.

Install a new gasket on the timing case.

Secure with bolts.

Press the gasket in the area where the silicon (gray) sealant will be applied.

Apply a bead of silicone sealant (grey) to the timing case/cylinder block approximately 2mm thick (dimension I).

Installing the cylinder head

Insert special tool KM-955-1 through the hole in the valve timing housing.

Insert the chain tensioner along the tension bar.

Install the pin into the guide.

Secure the cylinder head.

Tighten the new cylinder head bolts a few turns.

Install the timing case.

Note: Correct the position of the cylinder head by lightly tapping it with a rubber hammer in the direction of the timing case.

Tighten the 3 bolts to 8 Nm.

Tighten the 12 cylinder head mounting bolts to a torque of 25 Nm, further turning by +60° +60° +60°.

Pay attention to the correct tightening sequence.



The installation of the remaining components is carried out in the reverse order of removal.