Removal and installation the cylinder head (Opel Vectra C)

Caution! Cylinder head removal operations should only be performed when the engine is cold (ambient temperature) engine!

Note: Opel supplies models equipped with petrol engines only to the Russian car market through its official dealerships. At the time of publication of the Manual, official dealers cannot provide sufficient materials on repairing diesel engines. This section provides a detailed description of the procedure for removing the cylinder head of petrol engines. Information on some diesel engines is missing.

Engines Z16XE/Z18XE

1. Disconnect the cable from the negative battery terminal and remove the engine cover.

2. Remove the timing belt, however, if there is no need to replace the belt, the right engine support does not need to be removed. Unscrew the mounting bolt and remove the timing belt guide roller from the intake camshaft side.

3. Drain the coolant.

4. Remove the exhaust system.

5. Disconnect the electrical connectors of the oil pressure and level sensors and the crankshaft sensor.

6. Loosen the bolt and remove the air intake bracket. Loosen the generator mounting nut.

7. Remove the ignition module.

8. Disconnect the lambda probe wiring, disconnect 2 crankcase ventilation hoses, disconnect the air preheating hose from the throttle body. Unscrew the 10 mounting bolts and remove the cylinder head cover. On the Z18XE engine, remove the air intake tract.



9. Remove the camshaft timing gears and remove the rear timing belt cover.

10. Disconnect the fuel tank ventilation hose. Unscrew the mounting bolt and move the generator back. Loosen the mounting clamp and remove the cooling system hose (see illustrations).





11. Release the pressure in the fuel system through the service nipple using a special tool KM-J34730-91 (see illustration).





12. Disconnect the fuel line from the fuel distribution line using a tool KM-796A (see illustration).



13. Disconnect the engine management system wiring and ground bus.

14. Remove the power steering vacuum line and heater return hose.

15. Disconnect the upper radiator hose from the thermostat housing.

16. Unscrew 3 bolts and remove the heat shield of the exhaust manifold, unscrew 9 nuts (on the Z18XE engine - 10 nuts) and remove the manifold.

17. Disconnect the crankcase ventilation hose mounting bracket from the cylinder head. If necessary, remove the engine oil dipstick tube.

18. Loosen the cylinder head mounting bolts in the reverse order to that shown in Illustration 11.18 in two steps: loosen the bolts by 90° on the first approach and by 180° on the second approach; then completely unscrew the bolts and remove the cylinder head. If necessary, use an assistant.





19. Installation is performed in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections with the required force. When installing the cylinder head, use new mounting bolts. Tightening the cylinder head mounting bolts is performed in the sequence shown in the accompanying illustration in 5 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device.

Engines Z22YH/Z22SE/Z20NET

Note: The procedure for removing/installing the drive chains for the Z22YH engine is described below. On the Z20NET engine, instead of the ignition module, 4 ignition coils are installed, separately for each spark plug, - features (below are not given) dismantling/installation are related only to these elements. On the Z22SE engine there may be differences in the location and fastening of some lines and sensors.

20. Disconnect the wire from the negative terminal of the battery, remove the engine cover, remove the engine oil dipstick tube.

21. Remove the right front wheel and the front section of the exhaust system.

22. Release the 2 power steering lines from the holders on the subframe, unscrew the 2 bolts and remove the air intake tract bracket.

23. Install the right engine mount remover.

24. Drain the coolant.

25. Set the TDC for the piston of the first cylinder.

26. Remove the camshaft sensor and right engine mount.





27. Remove the upper timing chain guide and tensioner. Secure the exhaust camshaft sprocket with wire (see illustration), unscrew and remove the mounting bolts of both sprockets.

28. Unscrew the plug and the upper bolt of the timing chain guide (see Section 8).

29. Remove the 4 side bolts (1114), then loosen the head mounting bolts in the reverse order shown in Fig. 11.31 (10 to 1) in two steps - on the first approach, loosen the bolts on 90°, and for the second - by 180°, then completely unscrew the bolts and remove the cylinder head.

30. Installation is carried out in the reverse order of removal, replacing all seals of the removed components. Tighten the threaded connections to the required torque. When installing the cylinder head, use new mounting bolts. The chain tensioning procedure is described in Section 8.

31. Tightening of the cylinder head mounting bolts is performed in the sequence shown in the accompanying illustration from 1 to 10 in 4 steps: at the first approach, tighten the bolts using a torque wrench, and at subsequent ones, using a special angle measuring device. New bolts must be used.





32. Insert 4 bolts into the timing case, having previously lubricated their threads with a locking compound, and tighten in sequence from 11 to 14 with force 35 Nm (see illustration 11.31).

Note: Before installing the bolts, carefully clean the threads of the holes from any remaining old compound.

Z32SE Engine

33. Disconnect the cable from the negative terminal of the battery.

34. Raise the car on a lift, remove the right front wheel and drain the coolant.

35. Remove the multi-rib belt cover and remove the exhaust system, using one or, if necessary, two assistants.

36. Remove the exhaust (outer) camshafts.



37. Unscrew the 12 mounting bolts and remove the intake manifold flange installed in the cylinder block collapse (see illustration) Strictly follow the sequence of loosening the bolts. Close the air intake tract openings.

38. Remove the 2 mounting bolts and detach the flange (see illustration) cooling systems.





39. Disconnect the electrical wiring connectors (see illustration). unscrew the 4 bolts securing the engine control module and remove the module. Then unscrew the 2 bolts and remove the bracket securing the module to the engine block.



40. Remove 3 bolts and end plate (see illustration).

Attention! The upper tension roller of the toothed belt must remain on the plate!

41. Remove the bolts (see illustration) and remove the rear timing belt cover. Remove the engine oil dipstick tube.





42. Loosen the cylinder head mounting bolts in the reverse order to that shown in Illustration 11.19 in two steps: loosen the bolts by 90° in the first step and by 180° in the second step; then completely unscrew the bolts and remove the cylinder head. If necessary, use an assistant.

43. Installation is performed in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force. When installing the cylinder head, use new mounting bolts. Tightening the cylinder head mounting bolts is performed in the sequence shown in Illustration 11.19 in 5 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device.

Engines Y20DTH/Y22DTR

Removal and installation

44. Disconnect the cable from the negative terminal of the battery.

45. Raise the car on a lift, remove the right front wheel, remove the crankcase guard and drain the coolant.

46. Drain the engine oil.

47. Remove the exhaust system, using the help of one, or if necessary, two assistants.

48. Remove the multi-rib belt. Unscrew the 2 bolts and remove the belt tensioner.

Caution! The removed tensioner must be stored in a vertical position only, otherwise oil may leak out of the hydraulic damper!

49. Remove 2 bolts and loosen the nut securing the starter heat shield and remove the shield.

50. Loosen the 2 nuts and disconnect the supply lines of the electrical wiring from the generator, disconnect the connector (see illustration) engine oil pressure sensor wiring, unscrew the mounting bolt and disconnect the generator cable channel box.



51. Loosen the generator lower mount bolt and nut, place a suitable container under the engine and disconnect the line (see illustration 11.50) supply oil to the turbocharger.

52. Remove the upper and lower intake manifold bracket mounting bolts and disconnect it.

53. Unscrew the 2 mounting bolts, loosen the mounting clamps and remove the cooling system hose located on the front (in the direction of the vehicle's movement) side of the engine. Remove the coolant hose from the thermostat housing.

54. Lower the vehicle and remove the engine cover (see Section 2).

55. Release the brake booster vacuum line from its holders and remove it, loosen the mounting clamps, unscrew the 2 mounting bolts and remove the upper turbocharger air duct pipe.

56. Disconnect using the tool KM-717 (see illustration 7.6 in Chapter 5) electrical wiring from glow plugs.

57. Remove the air cleaner.

58. Loosen the clamps and disconnect the upper radiator hose and heater hoses. Disconnect the wiring from the coolant temperature sensor.

59. Disconnect the oil hose (see illustration), unscrew 2 bolts, disconnect quick-release connections using the device KM-796 and disconnect the fuel lines.



60. Disconnect the 2 vacuum lines from the vacuum reservoir, disconnect the wiring from the A/C pressure switch, the cable tray and the coolant line from the engine head.

61. Remove 2 bolts and disconnect the engine control module wiring.

62. After unscrewing the mounting bolts, remove the heat shields of the intake air duct and exhaust manifold.

63. Disconnect the return oil line (see illustration) turbocharger, - while the exhaust manifold should not be removed.



64. Loosen the generator mount and move it back. Loosen the nut and disconnect the electrical wiring from the starter.

65. Loosen the mounting clamps and disconnect the 2 hoses (see illustration) cooling systems.



66. Loosen the mounting clamps and remove the connecting hose of the turbocharger air duct and the inlet manifold.

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67. Disconnect the electrical wiring from the exhaust gas recirculation (EGR) valve.

68. Disconnect all supply lines, unscrew 4 bolts and remove the inlet pipe (see illustration).



69. Unscrew the union and mounting bolts and disconnect 4 injector fuel lines, unscrew 4 bolts and remove the vacuum pump. Disconnect the remaining electrical wiring connectors of the sensors installed on the cylinder head and some other lines that interfere with removing the head.

70. Remove the cylinder head cover by unscrewing 8 bolts and removing the washers. Raise the car on a lift and remove the fuel injection pump sprocket cover.

Attention! When installing the cover, apply sealant to its back side! To separate the cover, use a wide spatula or other suitable tool, do not apply much force, otherwise deformation of the cover will lead to oil leakage in the future!

71. Remove the A/C compressor bracket mounting bolt, release the 2 power steering lines from the holders on the subframe and install the tool to remove the right engine mount.

72. Remove the camshaft sensor and remove the right engine mount.

73. Remove the camshaft sprocket.

74. Remove 4 additional bolts (see illustration), then loosen the head mounting bolts in the order shown in two steps - on the first approach, loosen the bolts on 90°, and for the second - by 180°, then completely unscrew the bolts and remove the cylinder head. If necessary, use the help of an assistant.



75. Before installing the head, it is necessary to perform the inspection procedure (see below) and select the appropriate gasket.



76. Installation is performed in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force. When installing the cylinder head, use new mounting bolts. Tighten the cylinder head mounting bolts in the sequence shown in the accompanying illustration in 6 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device. Additional head mounting bolts are tightened in 3 steps.

Examination

77. After removing the head, it is necessary to clean the mating surfaces of the head and engine block and check them for surface deformation using a device with a flat straight edge (see illustration).



78. The thickness of the new cylinder head gasket is of particular importance for this engine. To obtain the optimum combustion chamber volume, the engine pistons protrude slightly on the block surface at their TDC. To prevent the piston and timing valves from touching during operation, it is necessary to provide the appropriate clearance.

79. To measure the height of the piston protrusion above the block surface, it is necessary to install devices on the block surface (see illustration) and set "0" on the plunger-type meter scale at the moment when the meter probe touches the block surface.



80. Measure the protrusion height of all pistons one by one, taking measurements at two points on each piston (see illustration 11.79) - for measurement it is necessary to select points (3 and (4) or another pair - (5) and (6). During measurement it is necessary to smoothly rotate the crankshaft to determine the highest point of lift. Based on the results of all measurements, select the greatest value of piston lift. After completing the procedure, rotate the crankshaft by 60° counterclockwise.



81. Determine the thickness of the new gasket according to the data in the table. The corresponding markings (notches) are applied to the gaskets (see illustration).

Z19DT(H) Engines

82. Tightening of the cylinder block mounting bolts is performed in the sequence shown in the accompanying illustrations in 5 steps: during the first and second approaches, tighten the bolts using a torque wrench, and during subsequent approaches, use a special angle measuring device.

Y30DT Engine

83. Remove the camshaft housing first from one cylinder head, then from the other.

84. In addition to the above work, when preparing the heads for removal, it is necessary to drain the engine oil, remove the multi-ribbed belt and its guide roller, remove 12 valve tappets, loosen the generator mount and move it back. Carefully inspect the heads, make sure that nothing interferes with their removal.

85. Unscrew the head mounting bolts in the reverse order shown in Illustration 11.88 and remove the corresponding head.

Attention! The bolts have different lengths - remember or mark their installation locations!

86. Before installing the heads, clean the head and block. Check the mating surfaces and the piston protrusion height. The checking procedure is essentially the same as described above for the Y20DTH/Y22DTR engines - the same devices are used. The measurement points are shown in the accompanying illustration.



87. Determine the thickness of the new gasket according to the data in the table. The corresponding markings (notches) are applied to the gaskets (see illustration). On the gaskets for the right head (13-5 cylinders) the marking is "R", and for the left head - "L".



88. Installation is performed in the reverse order of removal, replacing all sealing gaskets of the removed components. Tighten the threaded connections to the required force. When installing the cylinder head, use new mounting bolts. Tighten the cylinder head mounting bolts in the sequence shown in the accompanying illustration in 5 steps: during the first approach, tighten the bolts using a torque wrench, and during subsequent ones, using a special angle measuring device. Positions 1 through 4 should be occupied by long bolts, and positions 5 through 8 by short bolts!

Attention! Bolts of different lengths reach different angles!

• 1st step: Bolts 1 to 8 - 39 Nm
• 2nd step: Bolts 1 to 4 - 130°
• Step 3: Bolts 5 through 8 - 110°
• Step 4: Bolts 1 through 4 - 130°
• Step 5: Bolts 5 through 8 - 110°