Removal and installation the cylinder head of a 16-valve engine (Opel Kadett E)

Removal

Disconnect the wire from the negative terminal of the battery.

Remove the mass air flow meter with the mounting bracket and the air hose connecting the meter to the air filter.

Remove the air supply hose to the air filter and the air filter. Remove the plug from the expansion tank, disconnect the outlet hose from the radiator and drain the coolant into a container.

Disconnect the throttle cable. Disconnect the cables and hoses from the head.

Remove the exhaust manifold.

Remove the camshaft drive belt as shown below.

Remove the spark plug cover and disconnect the wires from the spark plugs.

Remove the cylinder head cover.

Loosen the bolts securing the camshaft toothed pulleys, holding the shafts with a wrench by the hexagon made on them, and remove the pulleys.

Remove the timing belt tension roller, remove the support roller and tapered roller spacers.

Remove the rear timing belt cover.

After the engine has cooled to a temperature no higher than 60°C (the temperature that can be maintained by the hand when touched) loosen all head mounting bolts by ¼ turn in the order shown in the figure, then loosen them by another ½ turn. Loosen the bolts completely and remove the steel washers.

Remove the head from the cylinder block, first separating it at points located on the 1st and 4th cylinders on the exhaust camshaft side.

Remove the cylinder head gasket.

Installation

Clean the mating surfaces of the cylinder head with a cleaner (for example, Decaploc 82). Never use cutting or abrasive tools to clean the surface of aluminum parts



Install the cylinder head gasket without sealant with the "Oben-Top" ("Top") mark facing up, orienting it towards the camshaft drive.

Install the cylinder head in place.

Tighten the ten head mounting bolts with washers, having previously lubricated the bolt threads and the rod under the head with engine oil. Do not lubricate the washers. Tighten all the bolts evenly in the order shown in the figure until resistance appears using a head with a hexagonal recess for the MKM 604-18 key, tighten the bolts in order in several stages (see subsection "Design and technical characteristics").

Install the rear cover of the timing belt and tighten its mounting bolts to a torque of 0.6 kgf·m, having first lubricated the threads of the bolts with a locking compound.

Install the timing belt tensioner and support rollers

Install the camshaft pulleys so that the marks on the pulleys and the drive pins on the shaft flanges are facing upwards (see picture).



Holding the camshafts with a wrench by the hexagon, tighten the pulley mounting bolts to a torque of 5.0 kgf·m, then turn them an additional 60-75°.

Install the cylinder head cover with a new gasket and tighten the mounting bolts to a torque of 0.8 kgf·m.



Connect both crankcase ventilation hoses.

Connect the wires to the spark plugs and put the spark plug protective cover back in place.

Install the exhaust manifold.

Place the timing belt on the pulleys and adjust its tension as shown below.

Further installation of the cylinder head is carried out in the reverse order of removal.