Cylinder Head Replacement

Make

Vauxhall

Model

Astra J

Section

Engine mechanics - 1.3L Diesel › Repair Instructions - On Vehicle › Cylinder Head Replacement

EngineCylinder Head Replacement

Cylinder Head Replacement Special tools •  EN-301   Measure Bridge •  EN-470-B   Torque Angle Sensor Kit •  GE-571-B   Gauge For equivalent regional tools, refer to Special Tools . Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement . 2. Remove the coolant thermostat from the cylinder head. Refer to Engine Coolant Thermostat Replacement . 3. Remove the camshaft housing cover gasket. Refer to Camshaft Housing Cover Gasket Replacement . 4. Remove the valve lifter. Refer to Valve Lifter Removal . 5. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .            6. Remove the 2 exhaust pressure pipe clamps (2, 6). 7. Remove the exhaust pressure pipe bolt (5) from the throttle body support. 8. Remove the exhaust pressure pipe bolt (3) from the exhaust pressure sensor bracket (1). 9. Unclip the vacuum hose from exhaust pressure pipe (4). 10. Remove the exhaust pressure pipe (4).            11. Remove the 2 exhaust gas recirculation pipe bolts (1) from the exhaust gas recirculation valve cooler. 12. Remove the 3 exhaust gas recirculation pipe bolts (5) from the exhaust manifold. 13. Remove the exhaust gas recirculation pipe (3). 14. Remove the exhaust gas recirculation pipe seal (2). 15. Remove the exhaust gas recirculation pipe gasket (4).            16. Remove the 2 throttle body support bolts (2). 17. Remove the throttle body support (1).            18. Unclip the heater inlet hose (1) from the heater outlet hose (3). 19. Remove the heater outlet hose clamp (4). 20. Remove the heater inlet hose (1) from the exhaust gas recirculation valve cooler (2). 21. Disconnect the exhaust gas recirculation valve wiring harness plug. 22. Disconnect the exhaust gas recirculation valve actuator wiring harness plug. 23. Remove the exhaust gas recirculation valve actuator vacuum hose.            24. Remove the turbocharger oil feed pipe bolt (2) from the turbocharger (1). 25. Remove the 2 turbocharger oil feed pipe gaskets (3). 26. Remove the turbocharger oil feed pipe bolt (5) from the oil filter housing (7). 27. Remove the 2 turbocharger oil feed pipe gasket (6). 28. Remove the turbocharger oil feed pipe (4).            29. Remove the 2 turbocharger oil return hose clamps (3). 30. Remove the turbocharger oil return hose (2) from the turbocharger (1) and the oil filter housing (4).            31. Remove the 2 charge air cooler inlet air pipe bolts (3). 32. Remove the charge air cooler inlet air pipe (4) from the turbocharger (1). 33. Remove the charge air cooler inlet air pipe gasket (2).            Note:  Place clean rags (2) in the opening to prevent the bolt from falling into the timing case. 34. Remove the upper timing chain guide bolt (1).            35. Remove the 3 oil pump housing bolts (1) from the oil pump housing and the cylinder head.            36. Loosen the 10 cylinder head bolts in sequence as shown.            37. Remove and DISCARD the 10 cylinder head bolts (1). 38. Remove the cylinder head (2).   38.1 Carefully slide the cylinder head from the oil pump housing and remove it.   38.2 Carefully lever the cylinder head off the timing case gasket with plastic wedge and use a rubber mallet to knock it off the timing case. Place the cylinder head on wooden blocks with the help of a second person. 39. Remove the cylinder head gasket (3). 40. Secure the timing chain with a cable tie.            Note:  Do NOT damage the sealing lip (2). Make sure that no residues remain at the joint between the oil pump housing and cylinder block, and that no bits of the gasket fall into the timing case. 41. Remove the oil pump housing gasket carefully.   41.1 Cut into the elastomer sealing lips (arrows) using a sharp knife pressed against the cylinder head.   41.2 With a plastic spatula, loosen the gasket from the oil pump housing and carefully snap it off at the designated point (1).   41.3 Remove the oil pump housing gasket.   41.4 Remove any gasket residue and clean all sealing surfaces. 42. Remove the turbocharger. Refer to Turbocharger Removal . 43. Remove exhaust manifold. Refer to Exhaust Manifold Removal . 44. Remove 4 glow plugs. Refer to Glow Plug Removal . 45. Remove exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Removal . 46. Remove exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Removal . 47. Remove intake manifold. Refer to Intake Manifold Removal . 48. Disassemble the cylinder head. Refer to Cylinder Head Disassemble . Installation Procedure 1. Assemble the cylinder head. Refer to Cylinder Head Assemble . 2. Install intake manifold. Refer to Intake Manifold Installation . 3. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Installation . 4. Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Installation . 5. Install the 4 glow plugs. Refer to Glow Plug Installation . 6. Install the exhaust manifold. Refer to Exhaust Manifold Installation . 7. Install the turbocharger. Refer to Turbocharger Installation . Note:  Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material. 8. Clean the sealing surfaces. 9. Inspect the flatness of the cylinder head and the cylinder block sealing surfaces.            Note:  A second technician is required. 10. Set piston of cylinder 1 to TDC Note:  The timing chain must be tightened to prevent the chain from slipping when the crankshaft is turned.   10.1 Using a suitable tool (2), press the camshaft drive gear (1) up and fix.   10.2 Turn the crankshaft in the direction of engine rotation at the crankshaft balancer. Note:  Carefully lay the camshaft drive gear on the web on the timing case.   10.3 Release the timing chain.            11. Install the EN-301   bridge (2) along 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. 12. Measure the piston projection dimensions at all pistons.            13. Select the cylinder head gasket with the correct identification marks:   13.1 Piston projection 0.028 - 0.127 mm (0.001 - 0.005 in) , choose cylinder head gasket with identification mark - without holes.   13.2 Piston projection 0.128 - 0.227 mm (0.005 - 0.009 in) , choose cylinder head gasket with identification mark - one hole.   13.3 Piston projection 0.228 - 0.327 mm (0.009 - 0.013 in) , choose cylinder head gasket with identification mark - two holes.            14. Fit the NEW oil pump housing gasket.   14.1 Using a sharp knife, cut into the elastomer sealing lips (arrows) at the breaking points of the new gasket.            Note:  It is essential for the cutting tool (1) to have a straight cutting surface.   14.2 Cut the NEW oil pump housing gasket off at the breaking points (arrow).            Note:  The upper new gasket and the old lower gasket must not be allowed to overlap. 15. Fit the NEW oil pump housing gasket (1) to the contact surface between the cylinder block and the timing case until the seal lies flush on the cylinder block and timing case (arrows) and the holes in the gasket and the timing case match up.            16. Clean all sealing surfaces. Note:  If the sealing tab (2) is damaged, remove this with a suitable cutter and apply sealant to the timing case contact surface! 17. Apply silicone sealing compound to the transitions between the cylinder block and oil pump housing (1).            18. Fit the timing case gasket (1).   18.1 Place the NEW oil pump housing gasket (1) on the oil pump housing. Note:  The bolts must be inserted in the bores shown above the cylinder head.   18.2 Loosely install the 2 bolts (2) to fix the camshaft housing gasket.            19. Apply silicone sealing compound to the transitions between the engine block and oil pump housing (1). 20. Install the NEW cylinder head gasket. 21. Apply silicone sealing compound to the transitions between the cylinder head gasket and oil pump housing.            22. Install the cylinder head (2). 23. Loosely install the 10 NEW cylinder head bolts (1)   Carefully align the cylinder head to the timing case, using a rubber mallet. Note:  Do NOT tighten the bolts. 24. Install the 3 oil pump housing bolts to the cylinder head. Caution: Refer to Fastener Caution . Caution: Refer to Torque-to-Yield Fastener Caution .            25. Tighten the 10 cylinder head bolts in sequence as shown and in the following order:   25.1 Tighten the bolts in sequence as shown to 40 N·m (30 lb ft) .   25.2 Tighten in sequence as shown to an additional 90° . Use the EN-470-B   anglemeter .   25.3 Tighten in sequence as shown to an additional 90° . Use the EN-470-B   anglemeter .            Note:  Place clean rags (2) in the opening to prevent the bolt from falling into the timing case. 26. Install upper timing chain guide bolt (1) and tighten to 9 N·m (80 lb in) . 27. Remove the clean rags (2).            28. Install the charge air cooler inlet air pipe gasket (2). 29. Install the charge air cooler inlet air pipe (4) from the turbocharger (1). 30. Install the 2 charge air cooler inlet air pipe bolts (3) and tighten to 10 N·m (89 lb in) .            31. Install the turbocharger oil return hose (2) to the turbocharger (1) and the oil filter housing (4). 32. Install the 2 turbocharger oil return hose clamps (3).            33. Install the turbocharger oil feed pipe (4). 34. Install the 2 NEW turbocharger oil feed pipe gasket (6). 35. Install the turbocharger oil feed pipe bolt (5) to the oil filter housing (7) and tighten to 22 N·m (16 lb ft) . 36. Install the 2 NEW turbocharger oil feed pipe gasket (3). 37. Install the turbocharger oil feed pipe bolt (2) to the turbocharger (1) and tighten to 22 N·m (16 lb ft) .            38. Install the heater inlet hose (1) to the exhaust gas recirculation valve cooler (2). 39. Install the heater outlet hose clamp (4). 40. Clip in the heater inlet hose (1) to the heater outlet hose (3).            41. Install the throttle body support (1). 42. Install the 2 throttle body support bolts (2) and tighten to 9 N·m (80 lb in) .            43. Install the NEW exhaust gas recirculation pipe gasket (4) to the exhaust gas recirculation pipe. 44. Install the exhaust gas recirculation pipe seal (2) to the exhaust gas recirculation pipe. 45. Install the exhaust gas recirculation pipe (3). 46. Install the 3 exhaust gas recirculation pipe bolts (5) to the exhaust manifold and tighten to 9 N·m (80 lb in) . 47. Install the 2 exhaust gas recirculation pipe bolts (1) to the exhaust gas recirculation valve cooler and tighten to 25 N·m (18 lb ft) .            48. Install the exhaust pressure pipe (4). 49. Install the exhaust pressure pipe bolt (3) to the exhaust pressure sensor bracket (1) and tighten to 9 N·m (80 lb in) . 50. Install the exhaust pressure pipe bolt (5) to the throttle body support and tighten to 9 N·m (80 lb in) . 51. Install the 2 exhaust pressure pipe clamps (2, 6). 52. Clip in the vacuum hose to exhaust pressure pipe (4). 53. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement . 54. Install the valve lifter. Refer to Valve Lifter Installation . 55. Install the camshaft housing cover gasket. Refer to Camshaft Housing Cover Gasket Replacement . 56. Install the coolant thermostat to the cylinder head. Refer to Engine Coolant Thermostat Replacement . 57. Install the catalytic converter. Refer to Catalytic Converter Replacement .

11 Engine