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Sump Replacement > < Turbocharger Oil Return Pipe Replacement

Astra J

Cylinder Head Replacement (1.7L Diesel LPL and LPV)

Removal Procedure

1. Drain the coolant system. Refer to Cooling System Draining and Filling .
2. Remove the turbocharger with exhaust manifold. Refer to Exhaust Manifold Replacement .
3. Remove the fuel feed pipe from fuel pump to fuel rail. Refer to Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump .
4. Remove the 4 fuel injectors. Refer to Fuel Injector Replacement .
5. Remove the vacuum pump. Refer to Vacuum Pump Assembly Replacement .
6. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement .
7. Remove the camshaft timing pulley. Refer to Camshaft Timing Pulley Replacement .

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8. Detach the 2 vacuum hoses (3) from 2 vacuum regulator solenoid valves (2).
9. Remove the vacuum hoses from the 5 clips (1).

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10. Install the engine mount bracket (2) with engine mount bracket adapter (1).

Caution: Refer to Fastener Caution .
11. Install the 3 engine mount bracket bolts (3) and tighten to 60 N·m (45 lb ft) .

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12. Install the engine mount (5).
13. Install the 2 engine mount to body bolts (2).
14. Install the engine mount nut (1).
15. Install the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4).
16. Tighten the 2 engine mount to body bolts (2) and the engine mount nut (1) to 62 N·m (46 lb ft) .
17. Tighten the 3 engine mount to the engine mount bracket bolts (3) to 50 N·m (37 lb ft) + 60 - 70 degrees .
18. Remove the engine lifter from the right engine lift bracket.

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19. Remove the 2 timing belt rear cover bolts (2) from the camshaft housing (1).
20. Remove the camshaft housing. Refer to Camshaft Housing Removal .

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21. Remove the timing belt rear cover bolt (1) from the cylinder head.
22. Remove the cylinder head. Refer to Cylinder Head Removal .

Installation Procedure

1. Install cylinder head. Refer to Cylinder Head Installation .

Caution: Refer to Fastener Caution .

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2. Install the timing belt rear cover bolt (1) to the cylinder head and tighten to 10 N·m (89 lb in) .
3. Install the camshaft housing. Refer to Camshaft Housing Installation .

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4. Install the 2 timing belt rear cover bolts (2) to the camshaft housing (1) and tighten to 10 N·m (89 lb in) .

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5. Install an engine lifter (1) to the right engine lift bracket and apply tension to the engine lifter chain in order to support the engine.

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6. Remove the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4).
7. Remove the 2 engine mount to body bolts (2) and the engine mount nut (1).
8. Remove the engine mount (5).

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9. Remove 3 engine mount bracket bolts (3).

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10. Attach the 2 vacuum hoses (3) to the 2 vacuum regulator solenoid valves (2).
11. Install the vacuum hoses to 5 clips (1).
12. Install the camshaft timing pulley. Refer to Camshaft Timing Pulley Replacement .
13. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement .
14. Install the 4 fuel injectors. Refer to Fuel Injector Replacement .
15. Install the fuel feed pipe from fuel pump to fuel rail. Refer to Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump .
16. Install the vacuum pump. Refer to Vacuum Pump Assembly Replacement .
17. Install the turbocharger with the exhaust manifold. Refer to Exhaust Manifold Replacement .
18. Filling the coolant system. Refer to Cooling System Draining and Filling .

Sump Replacement > < Turbocharger Oil Return Pipe Replacement