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Engine Flywheel Replacement - 1.4L LDD > < Drive Belt Replacement

Astra J

Cylinder Head Replacement (1.4L LDD)

Special Tools

•  EN-470-B   Angular Torque Wrench
•  EN-34730-91   Pressure Tester
•  EN-955-1   Fixing Pin from EN-955   Kit
•  EN-956-A   Fixing Tool

For equivalent regional tools, refer to Special Tools

Removal Procedure

1. Open the hood.
2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove air cleaner assembly in compound with air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement and Air Cleaner Outlet Duct Replacement .
4. Raise vehicle by full height. Refer to Lifting and Jacking the Vehicle .
5. Remove exhaust manifold from exhaust front pipe and catalytic converter bracket. Refer to Exhaust Manifold Replacement .

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6. Unclip heater inlet hose from 2 retainer clips (1, 2).
7. Disconnect engine control module wiring harness from retainer clip (3).
8. Drain coolant fluid. Refer to Cooling System Draining and Filling .
9. Lower vehicle by full height.
10. Remove exhaust manifold from cylinder head. Refer to Exhaust Manifold Replacement .

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11. Disconnect engine control module wiring harness from intake manifold upper:
  •  Disconnect throttle body wiring harness plug (1).
  •  Disconnect evaporative emission canister purge solenoid valve wiring harness plug (2).
  •  Disconnect intake manifold runner solenoid valve wiring harness plug (4).
  •  Unclip engine control module wiring harness from intake manifold (3).
  •  Disconnect the 4 fuel injector wiring harness plugs (5).

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12. Remove engine control module wiring harness (1) from camshaft cover:
  •  Disconnect intake camshaft position sensor wiring harness plug (7).
  •  Disconnect intake camshaft position actuator solenoid valve wiring harness plug (6).
  •  Disconnect exhaust camshaft position sensor wiring harness plug (4).
  •  Disconnect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
  •  Disconnect engine coolant temperature sensor wiring harness plug (3).
  •  Disconnect engine oil pressure indicator switch wiring harness plug (2).
  •  Unclip engine control module wiring harness (1) from camshaft cover.

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13. Unclip heated oxygen sensor wiring harness plug (1) from retainer clip.
14. Disconnect from engine coolant temperature sensor wiring harness plug (7).
15. Disconnect ignition coil module wiring harness plug (2).
16. Disconnect manifold absolute pressure sensor wiring harness plug (6).
17. Remove ground cable bolt (3) and ground cable from cylinder head.
18. Disconnect engine control module wiring harness from retainer clip (4).
19. Lay engine control module wiring harness aside.
20. Disconnect brake booster vacuum pipe from intake manifold connector (5).

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21. Remove radiator inlet hose clamp (3).
22. Remove radiator inlet hose (4) from water outlet (2).
23. Remove engine coolant air bleed hose (1) from water outlet (2).

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24. Remove heater inlet hose clamp (1).
25. Remove heater inlet hose (2) from water outlet (3).

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26. Unclip radiator outlet hose quick connector clamp (2).
27. Remove radiator outlet hose (3) from engine coolant thermostat housing (1).
28. Place collecting basin underneath.

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29. Remove fuel injector rail cap (1).

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30. Relief fuel pressure. Use EN-34730-91   pressure tester (1).

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31. Remove fuel feed pipe (2) from fuel injector rail.
32. Unclip fuel feed pipe from retainer clip (1).
33. Remove fuel ventilation pipe (4) from evaporative emission canister purge solenoid valve.
34. Unclip fuel ventilation pipe from retainer clip (3).
35. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .
36. Remove the drive belt. Refer to Drive Belt Replacement .
37. Remove the water pump pulley. Refer to Water Pump Pulley Removal .

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38. Remove 5 engine front cover bolts (1, 2).
39. Remove 3 water pump bolts (3).
40. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .
41. Install engine mount. Refer to Engine Mount Replacement - Right Side .
42. Remove the ignition coil. Refer to Ignition Coil Replacement .
43. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
44. Set engine to TDC. Refer to Camshaft Timing Chain Inspection .
45. Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal .

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46. Remove the timing chain tensioner plug (1) from the engine front cover.

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Note:  Remove and reinstall the EN-953-A   fixing tool for this step.
47. Install a spanner (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to apply tension to the timing chain and hold.

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48. Install EN-955-1   pin (2) to the timing chain tensioner bore (1) in order to fix it.
49. Remove spanner from intake camshaft.

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50. Remove 2 upper timing chain guide bolts (1).
51. Remove upper timing chain guide (2).

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52. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of intake camshaft sprocket with a spanner (1).
53. Loosen the exhaust camshaft sprocket bolt while holding up with a spanner.

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54. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1).

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55. Remove the 2 camshaft sprockets (2) in compound with the timing chain (1) and deposit in engine front cover.

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56. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure:
  56.1 Loosen the cylinder head bolts 90° .
  56.2 Loosen the cylinder head bolts 180° .
57. Remove and DISCARD the 12 cylinder head bolts.
58. Move the cylinder head assembly slightly in direction of the transmission.

Note:  Mind the timing chain tensioner and the timing chain guide pin. A second mechanic is required.
59. Remove the cylinder head assembly.
60. Remove the cylinder head gasket.
61. Remove the assembly parts from cylinder head:
  •  Remove the EN-953-A   fixing tool .
  •  Remove the intake manifold. Refer to Intake Manifold Removal .
  •  Remove the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Removal .
  •  Remove the water outlet. Refer to Water Outlet Removal .
  •  Remove the engine oil pressure indicator switch.
  •  Remove the intake camshaft. Refer to Intake Camshaft Removal .
  •  Remove exhaust camshaft. Refer to Exhaust Camshaft Removal .
  •  Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Removal .
  •  Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal .
  •  Remove the 3 engine lift brackets.

Installation Procedure

1. Install the cylinder head assembly parts:
  •  Install the 3 engine lift brackets.

Caution: Refer to Fastener Caution .
  •  Install the 3 engine lift bracket bolts and tighten to 22 N·m (16 lb ft) .
  •  Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation .
  •  Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm Installation .
  •  Install the exhaust camshaft. Refer to Exhaust Camshaft Installation .
  •  Install the intake camshaft. Refer to Intake Camshaft Installation .
  •  Install the engine oil pressure indicator switch and tighten to 20 N·m (15 lb ft) .
  •  Install the water outlet. Refer to Water Outlet Installation .
  •  Install the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing Installation .
  •  Install the intake manifold. Refer to Intake Manifold Installation .
Note:  Adjust the camshafts by means of the hexagon and a spanner.
   
  •  Install the EN-953-A   fixing tool .

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2. Cut the 2 elastomer sealing lips (1) from engine front cover gasket.
3. Bend down the engine front cover gasket at the predetermined breaking points (arrows).
4. Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.
5. Inspect cylinder block and cylinder head for flatness. Refer to Cylinder Head Cleaning and Inspection and Engine Block Cleaning and Inspection .

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Note:  Refer to electronic parts catalogue to find a suitable sealing compound. When sealing compound is applied, the complete fastening procedure of the cylinder head should not take longer than 10 minutes.
6. Apply sealing compound to the shown areas (1). The thickness of the sealing bead should be 2 mm (0.0787 in) .

Note:  Mind the marking on the cylinder head gasket for top side.
7. Install the cylinder head gasket to engine block.

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8. Install 2 engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.
9. Install the NEW upper engine front cover gasket.
10. Apply sealing compound to the shown areas (2). The thickness of the sealing bead should be 2 mm (0.0787 in) .

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Note:  A second mechanic is required. Guide the timing chain guide pin (2) to the timing chain guide and the timing chain tensioner (1) with the installed fixing pin through the timing chain tensioner plug bore in engine front cover.
11. Install the cylinder head (3).
12. Loosely install 12 NEW cylinder head bolts.

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13. Adjust the cylinder head to the engine front cover. Use a rubber mallet.
14. Prefix the engine front cover to cylinder head by installing 3 bolts (1).
15. Tighten the 3 bolts (1) to 8 N·m (71 lb in) .

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16. Tighten the cylinder head bolts in the sequence as shown and in the following order:
  16.1 Tighten the cylinder head bolts to 35 N·m(26 lb ft) .
  16.2 Tighten the cylinder head bolts an additional 180° . Use EN-470-B   wrench .
17. Loosen the 3 bolts from engine front cover.

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18. Install the 5 remaining bolts to engine front cover and water pump.
19. Tighten the 5 engine front cover bolts (1, 2) to 8 N·m (71 lb in) .
20. Tighten the 3 water pump bolts (3) to 8 N·m (71 lb in) .
21. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side
22. Install the water pump pulley. Refer to Water Pump Pulley Installation
23. Install the drive belt. Refer to Drive Belt Replacement
24. Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side
25. Install the engine mount. Refer to Engine Mount Replacement - Right Side

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26. Install the 2 camshaft sprockets (2) in compound with the timing chain (1).

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Note:  Camshaft position exciter wheels should stay rotatable.
27. Install the 2 camshaft position exciter wheels (1) and the 2 camshaft sprocket bolts (2).
28. Adjust engine to TDC, tighten the camshaft sprockets and install upper timing chain tensioner guide. Refer to Camshaft Timing Chain Adjustment
29. Remove all special tools for timing chain adjustment and install and tighten the timing chain tensioner plug. Refer to Camshaft Timing Chain Adjustment
30. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Installation
31. Install the camshaft cover. Refer to Camshaft Cover Replacement
32. Install the ignition coil. Refer to Ignition Coil Replacement

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33. Clip fuel ventilation pipe to retainer clip (3).
34. Connect fuel ventilation pipe (4) to evaporative emission canister purge solenoid valve.
35. Clip fuel feed pipe to retainer clip (1).
36. Connect fuel feed pipe (2) to injector rail.

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37. Install fuel injector rail cap (1).

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38. Connect radiator outlet hose (3) to engine coolant thermostat housing (1). Clip quick connector (2).

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39. Install heater inlet hose (2) to water outlet (3).
40. Install heater inlet hose clamp (1).

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41. Install radiator inlet hose (4) to water outlet (2).
42. Install radiator inlet hose clamp (3).
43. Connect engine coolant air bleed hose (1) to water outlet (2).

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44. Connect brake booster vacuum pipe to intake manifold connector (5).
45. Connect manifold absolute pressure sensor wiring harness plug (6).
46. Connect ignition coil module wiring harness plug (2).
47. Install ground cable and ground cable bolt (3) to cylinder head and tighten to 8 N·m (71 lb in) .
48. Connect engine coolant temperature sensor wiring harness plug (7).
49. Clip engine control module wiring harness to retainer clip (4).
50. Clip oxygen sensor wiring harness plug (1) to retainer clip.

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51. Install engine control module wiring harness to camshaft cover:
  •  Clip engine control module wiring harness (1) to camshaft cover.
  •  Connect engine oil pressure indicator switch wiring harness plug (2).
  •  Connect engine coolant temperature sensor wiring harness plug (3).
  •  Connect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
  •  Connect exhaust camshaft position sensor wiring harness plug (4).
  •  Connect intake camshaft position actuator solenoid valve wiring harness plug (6).
  •  Connect intake camshaft position sensor wiring harness plug (7).

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52. Connect engine control module wiring harness to intake manifold upper:
  •  Connect the 4 fuel injector wiring harness plugs (5).
  •  Clip the engine control module wiring harness to intake manifold (3).
  •  Connect intake manifold runner solenoid valve wiring harness plug (4).
  •  Connect the evaporative emission canister purge solenoid valve wiring harness plug (2).
  •  Connect the throttle body wiring harness plug (1).
53. Install exhaust manifold to cylinder head. Refer to Exhaust Manifold Replacement
54. Raise vehicle by full height.
55. Install exhaust manifold to exhaust front pipe and catalytic converter bracket. Refer to Exhaust Manifold Replacement

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56. Clip engine control module wiring harness to retainer clip (3).
57. Clip heater outlet hose to 2 retainer clips (1, 2).
58. Lower vehicle by full height.
59. Install air cleaner assembly in compound with air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement and Air Cleaner Outlet Duct Replacement .
60. Connect battery negative cable.
61. Fill coolant fluid. Refer to Cooling System Draining and Filling
62. Check and correct engine oil.
63. Close the hood.

Engine Flywheel Replacement - 1.4L LDD > < Drive Belt Replacement