Vauxhall Workshop Service and Repair Manuals

Cylinder Head Gasket, Replace

Note:   The customer should be informed of the choice between ECOService and ECOService-Flex before the oil change.

  Remove

4.   Remove air cleaner housing (1) •   Disconnect wiring harness plug of mass air flow meter (3) – Unclip from retaining clip (arrow) •   Release clamp (4) •   Remove bolt (2) •   Detach front intake hose (5)

5.   Remove charge air pipe (1) •   Release 2x clamp •   Unscrew 2x bolt (arrows) •   Unclip wiring harness •   Detach hose

6.   Separate wiring harness plug for differential pressure sensor (1) and temperature sensor (3) Note:   On vehicles with diesel particle filter •   Unclip wiring harness from bracket (2)

7.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt

9.   Disconnect coolant temperature sensor wiring harness plug •   Unclip wiring harness from coolant pipe 10.   Detach coolant return hose from thermostat housing (1) •   Release clamp 11.   Detach upper coolant hose from thermostat housing •   Release clamp

12.   Detach brake servo vacuum line (1) •   Disconnect quick-release coupling 13.   Separate vacuum line vacuum pump (2)

14.   Remove fuel filter housing (2) •   Disconnect 4 lines (1) and (4) – Use KM-796-A •   Disconnect 2 wiring harness plugs – Housing cover (3) – Housing bottom (arrow) •   Close 4 fuel lines •   Remove fuel filter housing and place in suitable container

17.   Remove charge air pipe at intake manifold (1) •   Release clamp •   Unscrew 4 bolts (arrows)

18.   Detach 2x fuel line (1) •   Release 2x clamp

19.   Detach high pressure line (2) •   High-pressure line from high-pressure pump to fuel rail •   Loosen 2 union nuts 20.   Detach 4x high-pressure lines for injectors •   Loosen 8 union nuts 21.   Detach accumulator (1) •   Detach oil leak line •   Detach 2 return lines – Release clamp •   Use KM-796-A •   Unscrew 2x bolt (arrows)

22.   Detach 4x oil leak line •   Release 4x retaining clamp (arrows)

23.   Release 2x injector bracket (3) •   Unscrew 2 nuts (1) 24.   Remove 4 injectors Note:   The injectors (2) can only be removed in pairs (cylinder 1+2 or cylinder 3+4).

26.   Detach oil dipstick guide tube (2) •   Unclip vacuum line (1) •   Unclip wiring harness (3) •   Unscrew threaded pins (1)

27.   Detach oil separator (1) from cylinder block •   Unscrew 2 bolts

28.   Separate 2x coolant hose (1) from heater core •   Release 2x coolant hose in direction of arrow

29.   Remove oil filter housing heat shield •   Unscrew 2 bolts •   Unscrew nut

30.   Remove heat shield exhaust manifold (1) •   Unscrew nut •   Remove bolt – Remove engine transport shackle (2)

31.   Remove turbocharger oil return line (1) •   Screw in 4 bolts

32.   Detach catalytic converter (1) from transmission •   Detach catalytic converter bracket – Remove bolt (2)

33.   Remove turbocharger oil feed line (1) •   Unscrew 2 bolts •   Remove 4 gaskets

34.   Detach turbocharger (2) with catalytic converter (3) from exhaust manifold •   Unscrew 3x nut (1) Note:   Carefully lower turbocharger. Turbocharger is not removed completely.

35.   Remove coolant pipe (1) from heat exchanger •   Unscrew 2x bolts on heat exchanger •   Unscrew bracket on cylinder head 36.   Detach coolant pipe from cylinder head on gearbox side •   Unscrew bolt, bracket, coolant pipe •   Release clamp

37.	Remove right engine damping block

38.   Remove support for engine damping block (1) from cylinder head and cylinder block •   Unscrew 4 bolts (2)

39.   Unscrew closure bolt (1) 40.   Remove closure cap (2) •   Unscrew 4 bolts (arrows)

41.   Remove exhaust camshaft closure bolt from camshaft housing •   Remove bolt •   Clean 2x threads on closure bolt and camshaft housing

42.   Lock exhaust camshaft •   Screw reference drift EN-46781 (1) into exhaust camshaft Note:   Check for proper installation position! •   The reference drift used for fixing must be fitted in a horizontal position. Note:   As an aid, apply marking (2) to reference drift. •   Turn exhaust camshaft until reference drift fixing visibly engages Note:   Using a suitable tool through the opening in the timing case, turn the screw on camshaft drive gear for exhaust camshaft. Note:   The reference drift is securely engaged in the camshaft when it can no longer be turned.

44.   Lock the crankshaft •   Insert EN-46785 (1) through the opening in the bottom of the gearbox bell housing •   To fix EN-46785 , attach screw (2) to gearbox bolt screw head. •   Carefully turn crankshaft until EN-46785 engages in flywheel

46.   Detach drive gear for exhaust camshaft •   Detach drive gear screw (1) with suitable tool through the opening in the timing case. Note:   Do not unscrew bolt.

47.   Tighten timing chain tensioner •   Tighten timing chain tensioner (1) with a suitable tool and lock in pretensioned position with KM-955-1 (2).

48.   Detach sliding rail, timing chain, from cylinder head •   Remove bolt (1) Note:   With a clean cloth (2), prevent bolt from dropping into timing case.

49.   Detach exhaust camshaft drive gear from exhaust camshaft •   Remove bolt •   Remove drive gear from exhaust camshaft with a rigid angled wire (1).

50.   Detach timing case from camshaft housing •   Unscrew bolt, bracket (1) •   Unscrew 8 bolts (arrows)

51.   Remove camshaft housing (3) •   Unscrew 16x bolt (2) Note:   Note dissimilar bolt lengths •   Unscrew 2x threaded pin (1) •   Carefully detach camshaft housing from timing case using a rubber mallet •   Carefully detach gasket between camshaft housing and timing case from the camshaft housing using a plastic spatula •   Remove camshaft housing •   Remove gasket (4)

52.   Remove 16 roller cam followers (1) with valve play adjusters (2) Note:   Put down in removal order.

53.   Remove cylinder head •   Detach 10x bolts in sequence shown •   Carefully detach cylinder head from timing case using a rubber mallet •   Carefully detach gasket between cylinder head and timing case from the cylinder head using a plastic spatula •   Remove cylinder head •   Remove cylinder head gasket

54.   Remove timing case gasket Note:   Sealing lip (2) must not be damaged •   Cut the elastomer sealing lip (arrow) flush to the cylinder head using a sharp knife •   Detach gasket from timing case with a plastic spatula and carefully fold up at the nominal break point (1). •   Remove gasket. •   Remove gasket residue and thoroughly clean all sealing surfaces Note:   Ensure that no gasket residue remains at the joining points between the timing case and cylinder block, and that no gasket residue drops into the timing case.

  Install

55.   Cut elastomer sealing lip (arrow) at nominal break point of new gasket using a sharp knife.

56.   Separate new timing case gasket at lower nominal break point •   Separate gasket at both nominal break points (arrow) with pincers (1) Note:   The cutting tool must have a straight cutting surface.

Important:   The new upper gasket and old lower gasket must not overlap! 57.   Adapt new seal on timing case •   Adapt the new gasket (1) to the contact surface of cylinder block to timing case using pincers until the gasket lies flush on the cylinder block and timing case (arrow), and the holes in the gasket and timing case align

59.   Check cylinder head for plane surface •   Use straight edge and feeler gauge to check length and breadth of cylinder head sealing surfaces for torsion •   Maximum deflection is 0,10 mm 60.   Measure the height of the cylinder head •   Sealing surface to sealing surface •   Dimension l: = 105.45 –105.55 mm

61.   Check cylinder head for plane surface •   Use straight edge and feeler gauge to check length and breadth of cylinder block sealing surfaces for torsion

65.   Set piston of cylinder 1 to TDC •   Tighten timing chain Note:   Timing chain must be tensioned to prevent the chain slipping when the crankshaft is turned. – Using a suitable tool (2), press camshaft drive gear (1) up and fix Note:   2nd person required •   Turn crankshaft in direction of engine rotation at torsional vibration damper •   Release timing chain Note:   Carefully lay camshaft drive pinion on web on timing case

66.   Measure piston projection •   Place probe of MKM-571-B in position on cylinder block •   Set dial to zero – Note pretension – Determine high point by turning crankshaft •   Measure piston projection – Measure on all 4 pistons – Carry out measurement on two different locations (3 and 4) or (5 and 6)

Important:   The largest determined piston projection determines the selection of the cylinder head gasket with appropriate identification. 70.   Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Code 0.028 - 0.127 mm 0.67 - 0.77 mm no hole 0.128 - 0.227 mm 0.77 - 0.87 mm one hole 0.228 - 0.327 mm 0.87 - 0.97 mm two holes

71.   Apply sealant Important:   If the sealing tab (2) is damaged, remove with a suitable cutting tool and apply sealant to the timing case contact surface! •   Apply sealant to the contact surface of cylinder block to timing case (1)

72.   Attach timing case gasket Note:   Proceed to fit cylinder head gasket within 10 minutes due to sealant reaction time •   Place new gasket (1) on timing case •   For fixing, insert 2x bolts M6 (2) in timing case bores and tighten 2x nuts M6 hand-tight Note:   Bolts must be inserted in bores shown above cylinder head

73.   Attach new cylinder head gasket •   Apply sealant to cylinder block – At contact surfaces cylinder block to timing case (1) •   Apply cylinder head gasket Note:   Note guide bushings. •   Apply sealant to cylinder head gasket – At contact surfaces cylinder head gasket to timing case (1)

75.   Attach timing case to cylinder head •   Align cylinder head carefully to timing case using a rubber mallet •   Screw in 3x bolts (1) until cylinder head lies against timing case

76.   Attach cylinder head to cylinder block •   Tighten 10x bolts in sequence shown 40 Nm + 90°+ 90°

79.   Attach new camshaft housing gasket •   Clean all contact surfaces •   Apply sealant to the contact surface of cylinder head to timing case (1) •   Apply camshaft housing gasket Note:   Check 2x centring pins •   Apply sealant to contact surface of gasket, camshaft housing to timing case (1)

80.   Install camshaft housing •   Unscrew 2x screw connection on timing case gasket •   Apply camshaft housing •   Tighten 16x bolts in tightening sequence until camshaft housing lies flat on the cylinder head Note:   Do not tighten bolts yet Note:   Note longer bolt (14)

81.   Attach timing case to camshaft housing •   Carefully align camshaft housing to timing case using a rubber mallet •   Screw in 5x bolts (arrows) until camshaft housing lies on timing case

82.   Attach camshaft housing •   Tighten 16x bolts M7 according to tightening sequence 18 Nm •   Tighten 2 stud bolts (M8) 25 Nm

Important:   Contact surfaces of exhaust camshaft, drive gear, bolts and threads in exhaust camshaft must be free from oil and grease! 84.   Insert drive gear for exhaust camshaft •   Lay drive gear on exhaust camshaft with suitable tool •   Bolt in bolt Note:   Do not tighten yet

87.   Attach drive gear for exhaust camshaft •   Tighten bolt 150 Nm Note:   During tightening of the timing chain, a second person must tension the timing chain tensioner (1) with a suitable tool (2).

99.	Install right engine damping block

Important:   The following installation sequence must be observed 112.   Attach coolant hose to heater core •   Push on 2x quick-release fitting (1) to stop on connection port for heater core (2) Note:   Note colour marking applied •   Push 2x lock (3) for quick-release fittings to stop in direction of arrow at the same time as pressing the release button (4) – Colour rings (5) must be visible •   Check correct seat of quick-release fittings and visibility of colour rings (5)

113.   Clean 4 injector seats with EN-47632 •   Loosen dirt with brush side (1) •   Remove dirt with sponge side (2)

115.   Install 4 injectors Note:   Injectors can only be inserted in pairs (cylinder 1+2 or cylinder 3+4). •   Replace 4 injector seal rings (1)

139.	Top up and bleed cooling system