Cylinder head — removal and installation (engine in a car) (Opel Omega A)

Note: Use new cylinder head bolts when installing.

Removal

1. Disconnect the negative terminal from the battery.

2. Remove the air filter.

3. Drain the coolant.

4. Remove the cooling system hoses from the coolant regulator housing by loosening the clamps. Remove the thermostat housing.

5. Clean and remove the pipes leading to the fuel pump and injectors. Seal the holes with caps.

6. Disconnect the electrical wires from the fuel shut-off solenoid valve on the pump and from the glow plugs. Remove the glow plugs and injectors.

7. Loosen the mounting screws and remove the cylinder head cover.

8. Set the crankshaft to the TDC position. To do this, set the gearbox to neutral, apply the handbrake. Turn the crankshaft by the central bolt on the belt pulley in the direction of rotation. To turn the crankshaft, you can also engage 4th or 5th gear and move the car with the handbrake released. The crankshaft is set to the TDC position if the marks on the camshaft gear and on the flywheel are aligned with the pointer on the crankcase.

9. Remove the chain tensioner shoe from the drive mechanism box.

10. Remove the camshaft gear, holding the camshaft with a KM-143 key from the rear end.

11. Gradually unscrew all cylinder head bolts (see illustration).



12. Unscrew the 2 bolts securing the camshaft box to the cylinder head.



13. Remove the cylinder head (see illustration).



14. Remove the cylinder head gasket.

Note: The gaskets have different thicknesses. It is necessary to install a gasket of the required thickness. The latter is determined by the number of notches, which can be from 1 to 3.

Installation

15. Before installation, it is necessary to clean the mating surfaces of the head and cylinder block. At the same time, make sure that dirt does not get into the holes of the cylinder block (to do this, cover the holes with a rag).

16. Check the cylinder head and block for warpage using a steel ruler.

17. Apply a layer of sealant, for example Opel No.1503294, to the right and left sides of the junction of the cylinder block with the camshaft housing.

(Material provided by this website: opelbook)

18. Position the new cylinder head gasket so that the holes are not covered (see illustration). The new gasket should be the same thickness as the old one. A 1.3 mm thick gasket has 1 notch, a 1.4 mm thick gasket has 2 notches, and a 1.5 mm thick gasket has 3 notches.



19. Install the new cooling system rubber gasket on the right side.

Note: To prevent the rubber gasket from falling out when installing the head, coat the seat with bearing grease.

20. Install the cylinder head. Preliminarily check the position of the camshaft at TDC.

21. Install and tighten the cylinder head bolts (see illustration).



22. Tighten all bolts in two stages in a spiral sequence from the middle to the edges (see illustration).

Stage 1: Tightening force 100 Nm.
Stage 2:
Turbodiesel: Tighten 135° (¼ + 1/8 turn)
Diesel: Turn with a rigid wrench 90° (¼ turn)



23. Tighten the 2 cylinder head to camshaft housing screws to a tightening torque of 15 Nm.

24. Place the gear on the camshaft and tighten the mounting bolt to a tightening torque of 150 Nm, while simultaneously holding the camshaft from behind using the special tool KM-143.



25. Install the chain tensioner with a new sealing ring. Check the valve timing. Tighten the thermostat housing to 22 Nm. Install the glow plugs and injectors.

26. Blow out the fuel injection channel connections with compressed air. Tighten the union nut to a tightening torque of 25 Nm.

27. Connect the electrical connections and glow plug terminals.

28. Connect the exhaust pipe to the exhaust manifold. Fill with coolant. Warm up the engine to operating temperature. Check the coolant level at operating temperature. Check the cooling system hoses for leaks.

29. Turn off the engine and remove the cylinder head cover.

30. Tighten the cylinder head mounting bolts with the engine warmed up. Tighten the bolts with a rigid wrench without loosening them first and in a spiral sequence from the middle to the edges.

Diesel: 30°
Turbodiesel: 30° and then tighten the bolts by 30°.

31. Install the cylinder head cover.