Cylinder Head Installation (Engine mechanics - 1.3L Diesel)

Make

Vauxhall

Model

Astra J

Section

Engine mechanics - 1.3L Diesel › Repair Instructions › Cylinder Head Installation

EngineCylinder Head Installation

Cylinder Head Installation Special Tools •  EN-301   Measuring Bridge •  EN-470-B   Torque Angle Sensor •  GE-571-B   Dial Gauge •  EN-46778   Fixing Tool Crankshaft For equivalent regional tools, refer to Special Tools . Note:  Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material. 1. Clean the sealing surfaces 2. Inspect the flatness of cylinder head and cylinder block sealing surfaces            3. Install the EN-301   bridge (2) in compound with the GE-571-B   gauge (1). Note:  The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking. 4. Measure the piston projection dimensions at all pistons.            5. Select the cylinder head gasket with the correct identification marks:   5.1 Piston projection 0.028 - 0.127 mm (0.0011 - 0.005) , choose the cylinder head gasket with identification mark - without holes.   5.2 Piston projection 0.128 - 0.227 mm (0.005 - 0.00894) , choose the cylinder head gasket with identification mark - 1 hole.   5.3 Piston projection 0.228 - 0.327 mm (0.00898- 0.01287) , choose the cylinder head gasket with identification mark - 2 holes.            6. Turn the crankshaft in the engine direction of rotation until the EN-46778   fixing tool (1) to engage with the drilling at flywheel (2) and cylinder block.            7. Install the cylinder head gasket (3). 8. Install the cylinder head (2). 9. Loosely install 10 NEW cylinder head bolts (1).            Note:  Use a rubber mallet to adjust the cylinder head. The overhang of the timing side should be under 0.1 mm (0.00394 in) . 10. Align the cylinder head (1) to the engine block (3) with a straightedge (2). Caution: Refer to Fastener Caution . Caution: Refer to Torque-to-Yield Fastener Caution .            11. Tighten the 10 cylinder head bolts in sequence as shown and in the following order:   •  Tighten the bolts in sequence as shown to 40N·m (30 lb ft) .   •  Tighten in sequence as shown to an additional 90° . Use EN-470-B   anglemeter .   •  Tighten in sequence as shown to an additional 90° . Use EN-470-B   anglemeter .

11 Engine