Replacing the cylinder head (Opel Insignia A)

Removal

1. Open the hood.

2. Disconnect the negative battery terminal.

3. Remove the engine cover.

4. Unscrew two bolts (5).



5. Disconnect the following connectors:

• throttle bodies (4);
• four glow plugs (7);
• intake manifold pressure sensor (2);
• high pressure fuel pump (1);
• fuel rail (8);
• mass air flow sensor (9).

6. Remove the wire harness holders (10 pcs.) from the air cleaner assembly and from the bracket (shown by arrows in the figure).

7. Move the wiring harness to the side.

8. Remove the camshaft housing.

9. Remove the EGR valve heat exchanger.

10. Remove the catalytic converter.

11. Remove the turbocharger.

12. Remove the oil dipstick tube.

13. Remove the forced exhaust ventilation system pipeline.

14. Remove the radiator outlet hose.

15. Remove the fuel return hose.

16. Install the SN-49290 support, following the manufacturer's instructions.

17. Remove the timing belt.

18. Loosen the bolt (1) of the high-pressure fuel pump bracket.



19. Loosen the upper bolt of the oil separator of the forced ventilation system of exhaust gases.



20. Raise and secure the vehicle.

21. Remove the coolant drain hose from the oil radiator.

22. Disconnect the collector drive wire connector (1).



23. Lower the car.

24. Loosen the 10 cylinder head bolts in the sequence shown in the figure as follows:

• Loosen the cylinder head bolts by 90° (quarter turn).
• Loosen the cylinder head bolts another 180° (half a turn).

25. Completely unscrew and dispose of the 10 cylinder head bolts (2), then remove the cylinder head (3).

Caution: Be careful not to damage the guide pins (4) and (5).

26. Remove the cylinder head gasket (1).

27. Remove the following parts from the cylinder head:

• Intake manifold,
• Exhaust manifold.
• Rocker arms and tappets with hydraulic compensators.
• Water pump.

28. Loosen the bolt (2) and remove the bracket (1).



29. Loosen the mounting bolts (3) and remove the cooling system outlet (4) with the gasket (5).

Installation

Caution: Remove all contaminants from the cylinder head bolt threads. Failure to do so may result in damaged threads, insufficient tightening of threaded connections, or component damage.

Note.

• Do not use old cylinder head bolts.
• Do not use any sealants or additional gaskets other than those provided with the cylinder head gasket.
• The cylinder head gasket must be installed in the correct direction.

1. Clean the contact surfaces and remove all dirt and old gasket residue from the threaded holes, lubrication and cooling system channels.

2. Check the non-flatness of the cylinder block and cylinder head surface using a steel straightedge and a set of flat feeler gauges.

3. Install the cooling system outlet (4) with a new gasket (5).



4. Install the bolts (3) and tighten to a torque of 9 Nm.



5. Install the bracket (1).

6. Install the bracket bolt (2) and tighten to 9 Nm.

7. Install the following cylinder head parts:

• Intake manifold.
• Exhaust manifold.
• Roller rocker arms and tappets with hydraulic compensators.
• Water pump.

8. Check the correct selection of the thickness of the new cylinder head gasket (1) using the marks shown in the figure:

• without hole: 0.95 mm;
• with one hole: 1.05 mm;
• with two holes: 1.15 mm.

Note: Always install a new cylinder head gasket of the same thickness as before disassembly.

9. Install a new cylinder head gasket (1). The side with the "Top" mark must face up.



10. Install the cylinder head (3).

Note: Be careful not to damage guide pins (4) and (5) and not to confuse the cylinder block guide pins with the camshaft housing guide pins.

[Text copied from this portal: opelbook]

11. Install 10 new cylinder head bolts (2).

12. Tighten the 10 new cylinder head bolts in the sequence shown in the illustration as follows:

a) Hexagon head bolts:

• First step: tighten to 20 Nm.
• Second step: tighten to 65 Nm.
• Step 3: Using the EN 45059 tool, tighten by 90°.
• Step 4: Using the EN 45059 tool, tighten by 90°.
• Step 5: Using the EN 45059 tool, tighten by 90°.

B) Torx T60 bolts:

• First step: tighten the bolts to 20 Nm.
• Step 2: Tighten the bolts to 65 Nm.
• Step 3: Using the EN 45059 tool, tighten by 90°.
• Step 4: Using the EN 45059 tool, tighten by 90°.
• Step 5: Using the EN 45059 tool, tighten by 90°.
• Step 6: Using the EN 45059 tool, tighten by 90°.

13. Raise the car.

14. Install the coolant drain hose from the oil radiator.

15. Connect the electrical connector (1) of the manifold drive.



16. Lower the vehicle.



17. Install the upper bolt of the positive crankcase ventilation oil separator and tighten to 9 Nm.

18. Install the high pressure fuel pump bracket bolt (1) and tighten to 25 Nm.



19. Install the timing belt.

20. Remove support SN-49290.

21. Install the fuel return hose.

22. Install the radiator drain hose.

23. Install the positive crankcase ventilation system pipeline.

24. Install the oil dipstick tube.

25. Install the turbocharger.

26. Install the EGR valve cooler.

27. Install the camshaft housing.

28. Install the wiring harness and connect the following connectors:

• throttle bodies (4);
• glow plugs (7);
• manifold pressure sensor (2);
• high pressure fuel pump (1);
• fuel rail (8);
• mass air flow sensor (9).

29. Install 2 bolts (5).



30. Install the holders (10) on the air filter assembly and bracket (shown by arrows in the figure).

31. Install the engine cover.

32. Connect the negative battery terminal.

33. Close the hood.