Replacing the cylinder head (Opel Insignia A)

Removal

1. Remove the intake manifold.

2. Remove the exhaust manifold.

3. Remove the timing belt tensioner.

4. Remove the cylinder head cover.

5. Remove the two camshaft position sensors.

6. Remove two stars (or two phase shifters) camshafts.

7. Remove the rear timing belt cover.

8. Remove the engine cooling system thermostat housing.

9. Remove the cylinder head:

• Loosen the 10 cylinder head bolts in the sequence shown in the figure, loosening them by 90° the first time and by another 180° the second time.
• Remove the cylinder head and place it on a suitable base.
• Remove the cylinder head gasket.

Installation

1. Install the cylinder head:

• Clean the sealing surfaces of the cylinder head and check their flatness.
• Install the cylinder head gasket.
• Install the cylinder head.
• Install new cylinder head bolts.

Tighten the bolts (1) in five stages:

• First step: tighten all bolts to 25 Nm.
• Second stage: pull to 90°.
• Step three: pull to 90°.
• Step four: pull to 90°.
• Step five: extend to 45°.

Caution: Observe the tightening sequence of the cylinder head bolts.

2. Install the cooling system thermostat housing.

3. Install the rear timing belt cover.

4. Install the stars (or phase shifters) camshafts.

5. Install the camshaft position sensors.

6. Install the cylinder head cover.

7. Install the exhaust manifold.

8. Install the intake manifold.

9. Fill the engine cooling system.

10. Check and adjust the engine oil level.