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Cylinder Head Replacement - 1.6L LLU > < Camshaft Sprocket Replacement

Astra J

Cylinder Head Replacement (1.6L LDE, LXV, and 1.8L 2H0,LUW,LFH)

Special Tools

EN-45059   Torque Angle Sensor Kit

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the intake manifold. Refer to Intake Manifold Replacement .
2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement .
3. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
4. Remove the timing belt tensioner. Refer to Timing Belt Tensioner Replacement .
5. Remove the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
6. Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
7. Remove the 2 camshaft position actuator adjuster. Refer to Camshaft Position Actuator Adjuster Removal .
8. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Removal .
9. Remove engine coolant thermostat housing. Refer to Engine Coolant Thermostat Replacement .

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10. Loosen the 10 cylinder head bolts in sequence as shown.
  10.1 Loosen the 10 bolts 90° .
  10.2 Loosen the 10 bolts 180° .

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11. Remove the 10 cylinder head bolts (1).
12. Remove and DISCARD the cylinder head (2).
13. Remove and Discard the cylinder head gasket (3).

Installation Procedure

1. Clean the sealing surfaces.
2. Inspect for plane surface.
  •  Cylinder block, cylinder head
  •  Straight-edge, feeler gauge

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3. Install a NEW cylinder head gasket (3).
4. Install the cylinder head (2).

Caution: Refer to Fastener Caution .

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Note:  Note the correct tightening sequence.
5. Install 10 NEW cylinder head bolts (1).
6. Tighten the bolts in 5 passes, using the EN-45059   sensor kit :
  •  First pass to 25 N·m (18 lb ft)
  •  Second pass to 90°
  •  Third pass to 90°
  •  Fourth pass to 90°
  •  Fifth pass to 45°
7. Install engine coolant thermostat housing. Refer to Engine Coolant Thermostat Replacement .
8. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Installation .
9. Install the camshaft position actuator adjuster. Refer to Camshaft Position Actuator Adjuster Installation .
10. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement .
11. Install the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
12. Install the timing belt tensioner. Refer to Timing Belt Tensioner Replacement .
13. Install the camshaft cover. Refer to Camshaft Cover Replacement .
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement .
15. Install the intake manifold. Refer to Intake Manifold Replacement .
16. Fill the cooling system. Refer to Cooling System Draining and Filling .
17. Check and correct the engine oil.

Cylinder Head Replacement - 1.6L LLU > < Camshaft Sprocket Replacement