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Engine Replacement - Automatic Transmission > < Belt Idler Pulley Replacement - Engine Mount Side

Astra J

Cylinder Head Replacement

Special Tools

•  CH-49290   Mounting Engine / Transmission
•  EN-45059   Torque Angle Sensor Kit

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
Warning:  Refer to Battery Disconnect Warning .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

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4. Remove the 2 conduit bolts (5).
5. Disconnect following connections:
  •  from throttle body (4)
  •  from the 4 glow plugs (7)
  •  from manifold pressure sensor (2)
  •  from fuel injection pump (1)
  •  from fuel rail (8)
  •  from air mass sensor (9)
6. Remove the wiring harness retainer (10) from the air filter assembly and from the bracket (see arrows in picture).
7. Hang the wiring harness aside.
8. Remove the camshaft housing. Refer to Camshaft Housing Replacement .
9. Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
10. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
11. Remove the turbo charger. Refer to Turbocharger Replacement .
12. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
13. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Tube Replacement .
14. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement .
15. Remove the fuel return hose. Refer to Fuel Return Hose Replacement .
16. Install the CH-49290   mounting , for the assembly use attached installation manual.
17. Remove the timing belt. Refer to Timing Belt Replacement .

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18. Remove the fuel injection pump bracket bolt (1).
19. Remove the upper positive crankcase ventilation oil separator bolt.
20. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
21. Remove the engine oil cooler coolant outlet hose. Refer to Engine Oil Cooler Coolant Outlet Hose Removal .

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22. Disconnect the wiring harness plug (1) from the manifold actuator.
23. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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24. Loosen the 10 cylinder head bolts in the sequence as shown. Use the following procedure:
  24.1 Loosen the cylinder head bolts 90° .
  24.2 Loosen the cylinder head bolts 180° .

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Note:  Do not damage the guide sleeves (4) and (5).
25. Remove and DISCARD the 10 cylinder head bolts (2).
26. Remove the cylinder head (3).
27. Remove the cylinder head gasket (1).
28. Remove the assembly parts from the cylinder head:
  •  Remove the intake manifold. Refer to Intake Manifold Removal .
  •  Remove the exhaust manifold. Refer to Exhaust Manifold Removal .
  •  Remove the valve lifter roller in conjunction with lash adjuster. Refer to Valve Lifter Roller Removal .
  •  Remove the water pump. Refer to Water Pump Removal .

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29. Remove the bracket bolt (2) and the bracket (1).
30. Remove the water outlet bolts (3).
31. Remove the water outlet (4) in conjunction with the water outlet gasket (5).

Installation Procedure

Caution: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.


Note: 
•  Do not use the cylinder head bolts again. Install NEW cylinder head bolts during assembly.
•  Do not use any type of sealant on the cylinder head gasket, unless specified.
•  The cylinder head gaskets must be installed in the proper direction and position.

1. Clean the sealing surfaces and remove all remains of dirt and old gasket material from thread bores, water galleries and oil galleries.
2. Check the flatness of the cylinder head and cylinder block with a steel rule and inspect for damage to the sealing surfaces.

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3. Install the water outlet (4) in conjunction with a NEW water outlet gasket (5).

Caution: Refer to Fastener Caution .
4. Install the water outlet bolts (3) and tighten to 9 N·m (80 lb in) .
5. Install the bracket (1).
6. Install the bracket bolt (2) and tighten to 9 N·m (80 lb in) .
7. Install the assembly parts from the cylinder head:
  •  Install the intake manifold. Refer to Intake Manifold Installation .
  •  Install the exhaust manifold. Refer to Exhaust Manifold Installation .
  •  Install the valve lifter roller in conjunction with lash adjuster. Refer to Valve Lifter Roller Installation .
  •  Install the water pump. Refer to Water Pump Installation .

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Note:  Always take the same thickness like the old gasket.
8. Check the right thickness of the NEW cylinder head gasket (1). It is marked as shown in picture:
  •  without a hole: 0.95 mm (0.0374 in)
  •  with one hole: 1.05 mm (0.0413 in)
  •  with two holes: 1.15 mm (0.0452 in)

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Note:  Do not damage the guide sleeves (4) and (5) and do not confuse the engine block guide sleeves with the camshaft guide sleeves.
9. Install a NEW cylinder head gasket (1). The marking "Top" should point to the cylinder head.
10. Install the cylinder head (3).
11. Loosely install 10 NEW cylinder head bolts (2).

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12. Tighten the 10 NEW cylinder head bolts in following order:
Note:  The following tightening order applies to ribe cylinder head bolts.
  12.1 First pass in sequence to 20 N·m (15 lb ft) .
  12.2 Second pass in sequence to 65 N·m (48 lb ft) .
  12.3 Third pass in sequence to an additional 90° using the EN 45059   angle sensor .
  12.4 Fourth pass in sequence to an additional 90° using the EN 45059   angle sensor .
  12.5 Fifth pass in sequence to an additional 90° using the EN 45059   angle sensor .
Note:  The following tightening order applies to torx T60 cylinder head bolts.
  12.1 First pass in sequence to 20 N·m (15 lb ft) .
  12.2 Second pass in sequence to 65 N·m (48 lb ft) .
  12.3 Third pass in sequence to an additional 90° using the EN 45059   angle sensor .
  12.4 Fourth pass in sequence to an additional 90° using the EN 45059   angle sensor .
  12.5 Fifth pass in sequence to an additional 90° using the EN 45059   angle sensor .
  12.6 Sixth pass in sequence to an additional 90° using the EN 45059   angle sensor .
13. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
14. Install the engine oil cooler coolant outlet hose. Refer to Engine Oil Cooler Coolant Outlet Hose Installation .

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15. Connect the wiring harness plug (1) from the manifold actuator.
16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
17. Install the upper positive crankcase ventilation oil separator bolt and tighten to 9 N·m (80 lb in) .

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18. Install the fuel injection pump bracket bolt (1) and tighten to 25 N·m (18 lb ft) .
19. Install the timing belt. Refer to Timing Belt Replacement .
20. Remove the CH-49290   mounting .
21. Install the fuel return hose. Refer to Fuel Return Hose Replacement .
22. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement .
23. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Tube Replacement .
24. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
25. Install the turbo charger. Refer to Turbocharger Replacement .
26. Install the catalytic converter. Refer to Catalytic Converter Replacement .
27. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
28. Install the camshaft housing. Refer to Camshaft Housing Replacement .

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29. Install the wiring harness.
30. Connect the following connections:
  •  to throttle body (4)
  •  to the 4 glow plugs (7)
  •  to manifold pressure sensor (2)
  •  to fuel injection pump (1)
  •  to fuel rail (8)
  •  to air mass sensor (9)
31. Install the 2 conduit bolts (5).
32. Install the wiring harness retainer (10) to the air filter assembly and to the bracket (see arrows in picture).
33. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
34. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
35. Close the hood.

Engine Replacement - Automatic Transmission > < Belt Idler Pulley Replacement - Engine Mount Side