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

2.   Remove air cleaner housing (5) with air intake hose •   Detach wiring harness plug (2) from hot film mass air flow meter •   Detach air intake hose from air intake pipe – Release clamp (1) •   Detach air cleaner housing from wheel housing – Unscrew bolt (4) •   Detach water drain hose (3) from air cleaner housing – Release clamp

4.   Insert KM-6173 (3) •   Align support bearing (1) •   Raise support bearing until journal (2) sits flush in mount (4) •   Fasten KM-6173 – Screw in 2x bolts

5.   Attach KM-6001-A (1) Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body •   Slacken 4x bolts (arrows) in adjusting rails •   Insert KM-6001-A – Insert journals (2) and (5) in guide holes in front axle body •   Tighten 4x bolts in adjusting rails •   Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals Note:   The guide journals must be seated free from play in the support bearings

7.   Remove charge air pipe (1) •   Unscrew 6x bolts

8.   Detach wiring harness for injectors •   Disconnect 4x wiring harness plugs for injector (2) •   Unscrew 2x bolts (3) •   Disconnect 4x wiring harness plug for glow plug (1) with KM-717 •   Push wiring harness to one side

Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1) 10.   Remove high pressure lines (1), pressure chamber to injectors •   Unscrew 8x union nut with KM-812 or KM-6098 •   Take out pressure lines •   Seal 4x pressure chamber opening with protective cap •   Seal 4x injector opening with protective cap

11.   Detach fuel return line (1) •   Detach 4x fuel return line from injector – Press 4x retaining clamps in direction of arrow •   Detach fuel return line from pressure chamber •   Unscrew 2x bolts Note:   Note different bolt lengths •   Unscrew nut

12.   Remove rear right engine transport shackle (1) •   Unscrew 2x bolts

13.   Remove rear left engine transport shackle (1) •   Detach wiring harness – Unclip clip •   Unscrew bolt

14.   Remove throttle valve body (1) •   Detach charge air hose (3) – Release clamp •   Release bracket, throttle valve body (4) – Detach from throttle valve body – Release on camshaft housing •   Disconnect wiring harness plug (2). •   Unscrew 4x bolts

15.   Detach right front engine transport shackle (1) •   Unscrew bolt

16.   Disconnect wiring harness plug from EGR-actuator (1)

17.   Remove EGR-port (1) •   Detach coolant hose – Release clamp •   Unscrew 2x bolts Note:   Note different bolt lengths

18.   Remove 4x seals, connection for injectors (1) •   Unscrew 8x bolts

19.   Remove 4x seal, injectors (1) •   Unscrew 8x bolts

20.   Remove camshaft housing cover (1) •   Unscrew 11x bolts Note:   Note different bolt lengths

21.   Remove 4x injector (1) Note:   Mark injectors •   Remove 4x bracket, injector (2) – Unscrew 4x bolts Note:   If a heat protection sleeve (5) also has to be removed when removing an injector, the gaskets (3) must be replaced and the heat protection sleeve must be hammered into the cylinder head with KM-6357 (4)

22.   Detach wiring trough (4) from front toothed belt cover (top) •   Unscrew bolt (2) •   Detach wiring harness (3) – Disconnect camshaft sensor wiring harness plug – Release 2x clip •   Detach vacuum line (1) – Release 2x clip •   Unclip wiring trough in direction of arrow – Undo clip

23.   Detach front toothed belt cover (top) (4) •   Detach vacuum line (3) – Unclip 3x clip •   Unscrew 8x bolts Note:   Note different bolt lengths •   Remove camshaft sensor bracket (1) – Unscrew bolt (2)

24.   Remove engine damping block support •   Detach from engine damping block bracket – Unscrew 3x bolts (2) •   Detach from cylinder block – Unscrew 3x bolts (3) •   Remove engine damping block adapter (1)

25.   Remove coolant pump drive gear (1) •   Unscrew 3 bolts

27.   Detach torsional vibration damper (1) •   Unscrew 4x bolts Note:   Counterhold at bolt (2)

28.   Remove front toothed belt cover (lower) (1) •   Unscrew 3x bolts (2)

29.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC" Note:   Marking on toothed belt drive gear must align with projection on oil pump cover (arrows) •   Fix with TDC fixing bolt (M6) (1) camshaft drive gear •   Fix with TDC fixing bolt (M8) (2) high pressure pump gear

30.   Remove toothed belt •   Mark direction of rotation •   Slacken the toothed belt tension roller – Loosen bolt (1) •   Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow •   Fix toothed belt tension roller in pre-tensioned position – Tighten bolt

31.   Turn crankshaft 60° against the direction of engine rotation

33.   Remove camshaft sprocket •   Remove TDC fixing bolt (1) •   Unscrew bolt Note:   Counterhold with KM-6347 (2) in conjunction with KM-956-1 (3)

34.   Detach rear toothed belt cover from camshaft housing •   Unscrew 2x bolts (1)

35.   Remove camshaft housing •   Unscrew 17x bolt – Slacken in the order shown (1 - 17) 1/2 turn and then remove

Important:   Mark cup tappet, draw out of the cylinder head and set aside in order so that the cup tappets can be allocated to the valves when reinstalled 37.   Take out 16x cup tappet (1)

38.   Remove cylinder head bolts •   Unscrew 10x bolt Note:   Slacken bolts in a spiral in the order shown in stages of 1/2 to 1 turn

  Inspect

41.   Cylinder Block, Check for Plane Surface Note:   Check the sealing surface in length and width for sag and in the diagonals for distortion - use a straight edge

42.   Insert MKM-571-B (1) in KM-301 (2) Note:   Note pre-tension •   Adjust dial to zero

43.   Measure piston projection •   Place probe on cylinder block •   Measure piston projection on all 4 pistons – Perform measurements at two different points (1) and (2) or (3) and (4) – Determine highest point by turning the crankshaft

44.   Turn crankshaft 60° against the direction of engine rotation

  Install

Important:   The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking 45.   Replace cylinder head gasket Note:   2 different designs are available from Aftersales Piston projection Thickness of cylinder head gasket Size Number of holes   used New   Version I Version II 0.630 - 0.696 mm 1.350 mm 1.450 mm A - 1 0.697 - 0.763 mm 1.400 mm 1.500 mm B 1 2 0.764 - 0.830 mm 1.450 mm 1.550 mm C 2 3 •   Place cylinder head gasket in position – Note guide sleeves

Important:   Note correct tightening sequence 47.   Fasten cylinder head •   Tighten 10x new bolt 39.2 Nm + 60°+ 60° Note:   Tighten in the order shown in a spiral from inside to outside with MKM-610 and KM-470-B

49.   Install camshaft housing •   Replace gasket •   Attach to cylinder head and tighten in the order shown (1-17) – Tighten 12x bolt (M8) 21.6 Nm – Tighten 5x bolt (M10) 26.5 Nm

51.   Install camshaft sprocket Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket •   Tighten bolt 63.7 Nm Note:   Counterhold with KM-6347 in conjunction with KM-956-1 •   Screw in TDC fixing bolt

53.   Install toothed belt Note:   TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (6) and (7) must align •   Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4) and high pressure pump drive gear (2) to the camshaft sprocket (1) – Observe direction of rotation •   Slacken the toothed belt tension roller (3) •   Remove 2x TDC fixing bolt •   Turn crankshaft 60° against the direction of engine rotation •   Tighten toothed belt tension roller 38.2 Nm

54.   Timing, Check •   Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position •   The following factors must be present at the adjustment position Note:   If one of these factors is not present, the timing must be adjusted 1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear 2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear 3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover •   Remove 2x TDC fixing bolt

56.   Turn the crankshaft until the cam pair (1) and (2) faces upwards. 57.   Check valve lash with feeler gauge Note:   Valve lash must be checked at room temperature when the engine is cold. •   Test values: Intake valve/exhaust valve (0.35 - 0.45 mm) 58.   Adjust valve play •   Turn the bucket tappet until the tappet groove faces outwards Important:   Care should be taken that the valves do not strike the piston head •   Press down cup tappet with KM-6090 Note:   Note different tool designs for intake and exhaust valve – Marking - IN = intake side – Marking - EX = exhaust side •   Remove shim

59.   Example for determination of shim thickness: 1. Thickness of installed shim   3.15 mm 2. Measurement between cams and cup tappets + 0.45 mm     = 3.60 mm 3. Nominal valve play - 0.40 mm 4. Thickness of new shim = 3.20 mm 60.   Insert shim •   Coat new shim (7) with engine oil and insert in cup tappet with code facing down 61.   Check and adjust remaining valves •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (6) and (2) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (5) and (3) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (4) and (1) Note:   Valve lash must be checked again on all adjusted valves

Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper 64.   Install torsional vibration damper •   Tighten 4x bolt 19.6 Nm Note:   Counterhold against bolt, toothed belt drive gear

71.   Replace injector gaskets •   Rubber gasket (1) •   Copper gasket (2)

72.   Install 4x injector •   Install 4x brackets – Align injectors with EN-48560 (1)

74.   Fasten 4x injectors •   Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

77.   Apply sealing compound Important:   Oil return bore (2) may not be covered with adhesive sealing compound •   Apply adhesive sealing compound (white) to sealing surfaces (1) and (3)

78.   Install camshaft housing cover •   Replace gasket •   Tighten 9x bolt in the stated order (1...9) 9.8 Nm

79.   Install 4x new seal, injectors (2) •   Align seal for injectors Note:   Sealing lip of seal must be in full contact with the injector with no gaps (arrow) •   Coat 8x bolt head contact surface (1) with special grease (white) •   Tighten injector seal in 2 stages Note:   During the tightening process, press injector seal against the camshaft housing cover with your hand 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

80.   Install 4x new seal, connection for injectors Note:   Marking "UP" must point upwards •   Tighten 8x bolts

Important:   Seal ring (1) may not be displaced on installation 81.   Install EGR-port •   Replace gasket •   Tighten 2x bolt 24 Nm Note:   Note different bolt lengths •   Attach coolant hose – Fasten clamp