Note: When installing, use new cylinder head bolts.
Removing
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. Clear and remove the pipelines leading to the fuel pump and atomizers. Plug holes with caps.
6. Disconnect the electrical wires from the fuel shut-off solenoid valve on the pump and from the glow plugs. Remove glow plugs and injectors.
7. Turn off screws of fastening and remove a cover of a head of the block of cylinders.
8. Set the crankshaft to TDC. To do this, set the gearbox to neutral, apply the handbrake. Turn the crankshaft at the center bolt on the belt pulley in the direction of rotation. To turn the crankshaft, you can also engage 4th or 5th gear and, with the handbrake released, move the car. 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 while holding the camshaft with a KM-143 key from the rear end.
11. Unscrew gradually all the bolts of the cylinder head (see illustration).
12. Unscrew 2 bolts of fastening of a case of a cam-shaft to a head of the block of cylinders.
13. Remove the cylinder head (see illustration).
14. Remove the cylinder head gasket.
Note: Gaskets are available in various thicknesses. It is necessary to install a gasket of the required thickness. The latter is determined by the number of notches, they can be from 1 to 3.
Installation
15. Before installation it is necessary to clear the combined surfaces of a head and the block of cylinders. When doing this, 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 up a head and the block of cylinders on a distortion by means of a steel ruler.
17. Apply a layer of sealant on the right and left sides of the cylinder block to the camshaft box, for example, Opel No. 1503294.
18. Position the new cylinder head gasket so that the holes are not blocked (see illustration). The new gasket should be the same thickness as the old one. A gasket 1.3 mm thick has 1 notch, 1.4 mm thick has 2 notches and 1.5 mm has 3.
19. Install a new rubber gasket for the cooling system on the right side.
Note: To prevent the rubber seal from falling out when installing the head, coat the seat with bearing grease.
20. Install the cylinder head. First check the position of the camshaft at TDC.
21. Install and tighten the cylinder head bolts (see illustration).
22. Screw all bolts in two stages in a spiral sequence from the middle to the edges (see illustration).
Stage 1: Tightening torque 100 Nm.
Stage 2:
Turbodiesel: Tighten 135° (¼ + 1/8 turn)
Diesel: turn 90°with a hard wrench (¼ turn)
23. Tighten the 2 screws securing the cylinder head to the camshaft box with a torque of 15 Nm.
24. Put the gear on the camshaft and tighten the fixing bolt to 150 Nm while holding the camshaft at the rear with the special tool KM-143.
25. Install the chain tensioner with a new spacer ring. Check valve timing. Screw on the thermostat housing with a tightening torque of 22 Nm. Install glow plugs and injectors.
26. Blow out the connections of the fuel injection channels with compressed air. Screw on the swing nut with a tightening torque of 25 Nm.
27. Connect the terminals of the electrical connections and glow plugs.
28. Attach the exhaust pipe to the exhaust manifold. Fill with coolant. Warm up the engine to operating temperature. Check the coolant level at engine operating temperature. Check the tightness of the cooling system hoses.
29. Turn off the engine and remove the cylinder head cover.
30. Tighten the cylinder head bolts when the engine is warm. The bolts should be tightened with a rigid wrench without prior unscrewing 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.
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