Vauxhall Workshop Service and Repair Manuals

Cylinder Head, Remove and Install

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

1.	Remove exhaust manifold with turbocharger •   with manual transmission •   with automatic transmission

4.   Detach 2x hose (1) from cylinder housing cover •   Undo 2 clamps

5.   Remove cylinder head cover •   Unscrew 7x bolt (arrows) in a spiral from the outside inward

6.   Slacken cylinder head Important:   Undo cylinder head bolts in the order shown. •   Unscrew 10x bolt

  Inspect

8.   Clean sealing surface and remove sealant residue 9.   Check cylinder head for sag in length and width on the sealing surfaces and for distortion along the diagonals •   Use a straight edge •   Permissible unevenness – see Technical Data 10.   Measure height of cylinder head •   Sealing surface to sealing surface (measurement I) – see Technical Data

13.   Check for plane surface •   Check cylinder block sealing surfaces for sag in length and width and for distortion along the diagonals – With straight edge and feeler gauge •   Permissible unevenness – see Technical Data

14.   Adjust ignition TDC of cylinder 1 •   Use MKM-571-B (1), KM-301 (2) •   Insert MKM-571-B in KM-301 •   Place KM-301 with MKM-571-B on cylinder block •   Place probe of MKM-571-B on piston head •   Set dial to zero – Note pre-tension •   Turn engine in direction of rotation Note:   Determine highest point of cylinder 1 by turning the crankshaft. 15.   Measure piston projection •   Place probe of MKM-571-B on cylinder block •   Set dial to zero – Note pre-tension •   Measure piston projection – Measure on all 4 pistons – Perform measurements at two different points (3 and 4) or )5 and 6) – Determine highest point by turning the crankshaft

  Install

Important:   Set crankshaft to approx 60° before cylinder 1 TDC 16.   Turn crankshaft Important:   The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking 17.   Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Identification 0.020 - 0.100 mm 0.77 - 0.87 mm without hole 0.101 - 0.200 mm 0.87 - 0.97 mm one hole 0.201 - 0.295 mm 0.97 - 1.07 mm two holes •   Insert guide sleeves •   Place cylinder head gasket in position

20.   Fasten cylinder head •   Tighten 10x new bolt 65 Nm + 90° + 90° + 90° Note:   Initially tighten cylinder head to 20 Nm following tightening sequence (1-10). Torque serves to fix cylinder head to engine block.

26.	Install exhaust manifold with turbocharger •   with automatic transmission •   with manual transmission