Removal
Warning! Remove the cylinder head on a cold engine. Use new bolts to secure the cylinder head.
1. Depressurize the fuel system and remove the ground cable from the battery.
2. Drain the coolant from the cooling system and unscrew the spark plugs.
3. Remove the timing belt.
4. Remove the intake and exhaust manifolds. If disassembling the cylinder head is not required, it can be removed together with the manifolds. But to do this, you need to do the following:
(Original posted on the website: «OpelBook.ru»)
- disconnect the electrical connectors from the throttle body and manifold and release the wiring harness from the intake manifold;
- disconnect the fuel supply hoses from the throttle body and the coolant supply hoses to the intake manifold;
- unscrew the bolt from the intake manifold support hanger and the upper generator mounting bolt;
- disconnect the accelerator cable;
- unscrew the exhaust pipe from the exhaust manifold and disconnect the oxygen sensor.
5. Remove the cylinder head cover.
6. Remove the camshaft pulley.
7. Unscrew the bolts securing the rear timing belt cover to the camshaft housing.
8. Disconnect the electrical connectors from the DIS unit and the coolant temperature sensor.
9. Loosen the clamp and disconnect the coolant hose from the thermostat housing.
10. Check that all hoses, pipes and wires are disconnected from the cylinder head.
11. In the reverse order of tightening, gradually loosen the cylinder head mounting bolts.
12. Remove the camshaft housing from the cylinder head.
13. Remove the cylinder head from the cylinder block. Do not displace the tappets and axial pressure pads.
14. Remove the cylinder head gasket.
Preparing for installation
1. The mating surfaces of the cylinder head and block must be completely clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning, as the aluminum alloy is very easy to damage. Check that carbon deposits have not entered the oil and water passages. This is especially important for the lubrication system, as carbon deposits can block the supply of oil to engine components. Clean the passages if necessary.
2. Check the mating surfaces of the cylinder head and block for nicks, deep scratches and other damage. If the defects are small, they can be removed by mechanical treatment. However, if the defects are significant, the parts must be replaced.
3. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
4. Clean the bolt holes in the block. Driving a bolt into an oil filled hole can cause the block to burst due to hydraulic pressure.
5. Replace the cylinder head bolts regardless of their condition.
Installation
1. Check that the piston of the first cylinder is at top dead center.
2. Check that the two guide rods are installed in the cylinder block.
3. Install a new cylinder head gasket. The arrows indicate the position of the guide pins.
4. When installing, ensure that the TOR/OBEN marking is facing upwards.
5. Install the cylinder head onto the guide pins.
6. Check that the mating surfaces of the cylinder head and camshaft housing are clean and dry. Check that the timing mark on the camshaft pulley is at the top.
7. Apply a thin layer of sealant to the surface of the cylinder head that mating with the camshaft housing.
8. Lubricate the top of the levers with clean engine oil.
9. Install the camshaft housing onto the cylinder head.
10. Install the cylinder head bolts and tighten them hand tight.
11. Tighten the cylinder head bolts gradually and sequentially to the specifications specified in subsection 3.1.2.
12. Screw in the bolts securing the rear timing belt cover to the camshaft housing.
13. Install the camshaft pulley and timing belt.
14. Connect the electrical connectors to the cylinder head components.
15. Connect the coolant hose to the thermostat housing and secure with a clamp.
16. Connect the collectors.
17. Install the wheel and lower the vehicle.
18. Check that all pipes and hoses are securely connected and fill the cooling system with coolant and install the spark plugs.
19. Connect the battery, start the engine and check for leaks.
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