2. Remove the intake and exhaust manifolds as described in Section 3.
3. Remove the spark plugs, distributor cap and distributor rotor as described in Section 4.
4. Unfasten and remove the top cover of the timing belt.
5. Remove the thermally viscous cooling fan and drive belt as described in Section 2.
6. Unscrew the camshaft cover, remove the gasket. Note the location of the high-voltage wire hanger.
7. Turn the engine with a wrench on the crankshaft pulley bolt until the mark on the camshaft sprocket aligns with the pointer on the top of the rear timing belt cover. Also align the notch in the crankshaft pulley with the pointer on the bottom of the rear timing belt cover.
8. Loosen the three bolts securing the water pump to the block. Turn the water pump housing counterclockwise and remove the timing belt from the camshaft sprocket.
9. Secure the camshaft with a wrench, then loosen the clamp bolt and remove the sprocket.
10. Unscrew the rear cover of the timing belt from the cylinder head.
11. Loosen the clamps and disconnect the crankcase ventilation hose from the camshaft housing.
12. In a spiral from the outside to the inside, loosen each cylinder head bolt a quarter turn. Then in the same sequence, loosen the bolts a half turn, then remove them completely. Note that the cylinder head bolts must be replaced; prepare a new set of bolts for assembly.
13. Lift the camshaft housing and camshaft.
14. Lift the cylinder head from the block.
15. Remove the gasket from the block, clean the mating surfaces.
16. Check that pistons No.1 and 4 are still at top dead center.
17. Check that both location pins are inserted into the block. Place the new head gasket on the block with the "TOP" facing up and forward.
Information taken from the website (OPELBOOK)
18. Position the cylinder head on the block so that the pins fit into their holes. Check that the hydraulic valve lifters, thrust pads and rocker arms are positioned correctly.
19. Apply the joint compound to the mating surfaces on top of the cylinder head with a soft brush to ensure an even coating.
20. Lower the camshaft housing onto the head.
21. Insert the new cylinder head bolts, tighten them in the sequence shown in Figure 1.3 to the tightening torque specified in the Specification. Note that the bolts should be tightened to the initial torque, then gradually tightened to the specified angle.
22. Install the crankcase ventilation hose, tighten the clamps.
23. Insert and tighten the timing belt rear cover bolts.
24. Install the camshaft sprocket, tighten the bolt.
25. Check that the timing marks on the crankshaft pulley and camshaft sprocket are correctly aligned. Install the timing belt, being careful not to disturb the sprockets and creating some tension by moving the water pump clockwise.
26. Ideally, the tensioning tool recommended by GM (KM-510-A) should be used. If not, proceed as follows.
27. Turn the water pump clockwise to apply moderate belt tension, then tighten the bolts. Turn the crankshaft clockwise one half turn while pulling the belt between the crankshaft and camshaft sprockets. Install a tension gauge between the camshaft and water pump sprockets and check that the readings match the specifications.
28. If adjustment is necessary, move the water pump clockwise to increase tension or counterclockwise to decrease tension. Rotate the crankshaft one full revolution and repeat the test.
29. If you do not have a tool, check the tension by turning the belt 90° with your thumb and forefinger.
30. After adjustment, tighten the water pump bolts to the tightening torque specified in Specification (Section 2) and recheck the alignment of the timing marks.
31. Install the camshaft cover with a new gasket, then install the mounting bolts and washers, tighten them securely.
32. Install the thermal viscous cooling fan and drive belt, referring to Section 2.
33. Install the top cover of the timing belt.
34. Install the spark plugs, distributor cap and distributor rotor according to Section 4.
35. Install the intake and exhaust manifolds according to Section 3.
36. Connect the negative battery cable.
37. Start the engine and warm it up to normal operating temperature.
38. Stop the engine, tighten the cylinder head mounting bolts to the specified angle in the sequence shown in Figure 1.3. There is no need to re-tighten the bolts.
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