Vauxhall Workshop Service and Repair Manuals

Cylinder Head, Remove and Install

Note:   Only remove cylinder head with the engine cold

  Remove

3.   Remove air cleaner housing •   Disconnect mass air flow sensor wiring harness plug (2) •   Unclip tank vent line (3) •   Detach engine vent hose (4) from air intake hose – Release clamp •   Detach air intake hose (5) from throttle valve body – Release clamp •   Detach air cleaner housing – Unscrew bolt (1) – Unclip rubber mounting at the bottom – Remove air intake pipe (6)

4.   Disconnect wiring harness plug, throttle valve module (2) 5.   Detach coolant hoses (1) from throttle valve module •   Place collecting pan underneath. •   Undo 2 clamps 6.   Unclip coolant hose (3)

7.   Release fuel pressure with KM-J-34730-91 (2) via test connection •   Unscrew protective cap from test connection (1) •   Collect escaping fuel in a suitable container •   Comply with safety regulations and national legislation

8.   Detach fuel supply line (2) with KM-796 (1) from fuel distributor pipe •   Disconnect quick-release fitting 9.   Detach brake servo vacuum line (3) from intake manifold •   Disconnect quick-release fitting

10.   Detach tank vent valve line (1) from intake manifold

11.   Disconnect tank vent valve wiring harness plug (1)

12.   Detach front exhaust pipe (2) from catalytic converter •   Unscrew 3x nuts (1)

13.   Drain coolant •   Place collecting pan underneath. •   Attach suitable hose to drain connection (2) •   Open coolant drain screw (1) – Drain coolant •   Close coolant drain screw

14.   Disconnect wiring harness plugs (1), engine control unit •   Unlatch fuse (2) 15.   Detach 2x earth cable (4) •   Unscrew 2x nuts 16.   Disconnect 6x wiring harness plug, engine wiring harness •   Multi-plug (3), ignition module (5), oil pressure switch (6), coolant temperature sensor (7), camshaft sensor (8) •   Expose wiring harness

17.   Remove thermostat housing (2) from coolant pump •   Unscrew 3 bolts •   Remove gasket (3) 18.   Detach coolant hose (1) from radiator •   Release clamp

19.   Detach coolant hose (2) from EGR-valve (1) •   Release clamp

20.	Remove exhaust manifold (up to MY 2005.5)

21.	Remove exhaust manifold (from MY 2005.5)

22.   Remove oil filter •   Detach cover (1) from oil filter housing •   Remove oil filter insert (2) 23.   Detach oil filter housing (3) from cylinder block •   Unscrew 3x bolts (4) •   Remove gasket (5)

24.   Remove ribbed V-belt •   Mark direction of rotation •   Apply tension to ribbed V-belt tensioner (arrow) clockwise with KM-6131 •   Insert KM-955-2 (1) •   Relieve tension on ribbed V-belt tensioner

25.   Detach coolant pump belt pulley (1) from coolant pump •   Unscrew 3x bolts (2)

26.   Slacken timing case •   Unscrew 4x bolts, coolant pump (1) •   Unscrew 5x bolts, timing case (2) and (3) 27.   Remove camshaft sensor (5) from timing case •   Unscrew bolt (4)

28.   Remove engine vent hose (2) from cylinder head cover •   Release clamp 29.   Remove ignition module •   Disconnect cooling module wiring harness plug (4) •   Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow •   Unscrew 2x bolts (6) •   Remove ignition module (5) from spark plugs with KM-6009 (3) Note:   Do not tilt 30.   Detach cylinder head cover (7) from cylinder head •   Unscrew 13x bolts

31.   Remove locking screw cylinder block base plate (1) 32.   Lower vehicle 33.   Adjust TDC of combustion stroke of cylinder 1 •   Insert KM-952 (2) – Turn crankshaft evenly until KM-952 engages – Marking on the crankshaft belt pulley (4) must align with the cast projection (3) on the timing case

34.   Detach sliding rail (1) from cylinder head •   Unscrew 2x bolts 35.   Detach camshaft sprockets •   Unscrew 2x bolts (2) – Counterhold with open-ended wrench against the hexagon (3) of the camshafts •   Set aside camshaft sprockets with chain in timing case

36.   Remove cylinder head bolts Note:   Undo cylinder head bolts in the order shown •   Slacken 12x bolts, 90° •   Slacken 12x bolts 180°

38.   Cut away timing case gasket •   Cut through elastomer sealing lips (dimension I and II) of the timing case gasket with a sharp knife from inside to outside so that they are flush on the cylinder block •   Bend and snap gasket carefully at the fracturing points provided (arrows)

40.	Check cylinder head and cylinder block for flatness

42.   Adjust cylinder head gasket •   Cut away projecting elastomer (dimension I) on the timing side

  Install

43.   Cylinder Head Gasket, Replace Note:   After applying the silicone sealing compound, the cylinder head must be brought into position within 10 minutes and the cylinder head bolts and the timing case bolt must be screwed in loosely. •   Apply a bead of silicone sealing compound approx. 2 mm thick in the corner between the timing case/cylinder block •   Place new cylinder head gasket on cylinder block – With TOP/OBEN marking at the top – Press on in the area of the silicone sealing compound

44.   Adjust timing case gasket to fit at the top (1) •   Insert 2x bolt, timing case (arrows) •   Position new part gasket (1) on timing case – Use bolts to fix •   Press on in the area of the silicone sealing compound •   Apply a bead of silicone sealing compound in the corner between the timing case/cylinder head gasket – Approx. 2 mm thick (dimension I)

46.   Fasten cylinder head •   Screw in new cylinder head bolts a few thread starts •   Attach timing case. Note:   Position cylinder head in the direction of the timing case by striking it gently with a rubber mallet – Tighten 3x bolt (1) 8 Nm •   Tighten 12x cylinder head bolt 25 Nm + 60° + 60° + 60° – Note correct tightening sequence

48.   Fasten timing case •   Release lower 3 bolts (screws fitted beforehand) from cylinder head again •   Install coolant pump bolts – Tighten 4x bolt (1) 8 Nm •   Install timing case bolts – Tighten 5x bolt (2) and (3) 8 Nm •   Attach camshaft sensor (5) with new seal ring – Tighten bolt (4) 6 Nm

49.   Turn camshafts by the hexagon (short distance) until KM-953 (1) can be inserted in the grooves of the camshafts Note:   Turn camshafts carefully and evenly 50.   KM-953 must engage as far as the stop in the grooves of the camshafts

53.   Attach KM-954 to timing case •   Turn phase sensor disc (2) in such a way that KM-954 (1) can be inserted on the timing case •   Tighten 2x bolts 54.   Remove KM-955-1

55.   Fasten camshaft sprockets Note:   Tightening torque 10 Nm serves to fix the camshaft sprockets and the phase sensor disc temporarily •   Tighten 2x bolt (2) 10 Nm Note:   First of all tighten bolt of intake camshaft sprocket – Counterhold the camshafts on the hexagon (1)

62.   Apply sealing compound •   Disconnect projecting part of timing case gasket (1) flush with cylinder head/timing case •   Apply a bead of silicone sealing compound approx. 2 mm thick (dimension I) Note:   The cylinder head cover must be fitted within 10 minutes of applying the silicone sealing compound

63.   Attach cylinder head cover •   Insert new gasket (2) in cylinder head cover (1) •   Tighten 13x bolt 8 Nm Note:   Bolts must be checked visually to check whether the elastomer seal is damaged. If the elastomer seal is damaged, the bolt must be replaced with a new one.

70.	Install exhaust manifold (up to MY 2005.5)

71.	Install exhaust manifold (from MY 2005.5)

86.	Fill and bleed cooling system