Astra J
Cylinder Head Replacement (1.7L Diesel LPL and LPV)Removal Procedure
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1. | Drain the coolant system. Refer to Cooling System Draining and Filling . |
2. | Remove the turbocharger with exhaust manifold. Refer to Exhaust Manifold Replacement . |
3. | Remove the fuel feed pipe from fuel pump to fuel rail. Refer to Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump . |
4. | Remove the 4 fuel injectors. Refer to Fuel Injector Replacement . |
5. | Remove the vacuum pump. Refer to Vacuum Pump Assembly Replacement . |
6. | Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement . |
7. | Remove the camshaft timing pulley. Refer to Camshaft Timing Pulley Replacement . |
8. | Detach the 2 vacuum hoses (3) from 2 vacuum regulator solenoid valves (2). |
9. | Remove the vacuum hoses from the 5 clips (1). |
10. | Install the engine mount bracket (2) with engine mount bracket adapter (1). |
Caution: Refer to Fastener Caution . |
11. | Install the 3 engine mount bracket bolts (3) and tighten to 60 N·m (45 lb ft) . |
12. | Install the engine mount (5). |
13. | Install the 2 engine mount to body bolts (2). |
14. | Install the engine mount nut (1). |
15. | Install the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4). |
16. | Tighten the 2 engine mount to body bolts (2) and the engine mount nut (1) to 62 N·m (46 lb ft) . |
Caution: Refer to Torque-to-Yield Fastener Caution . |
17. | Tighten the 3 engine mount to the engine mount bracket bolts (3) to 50 N·m (37 lb ft) + 60 - 70 degrees . |
18. | Remove the engine lifter from the right engine lift bracket. |
19. | Remove the 2 timing belt rear cover bolts (2) from the camshaft housing (1). |
20. | Remove the camshaft housing. Refer to Camshaft Housing Removal . |
21. | Remove the timing belt rear cover bolt (1) from the cylinder head. |
22. | Remove the cylinder head. Refer to Cylinder Head Removal . |
Installation Procedure
1. | Install cylinder head. Refer to Cylinder Head Installation . |
Caution: Refer to Fastener Caution . |
2. | Install the timing belt rear cover bolt (1) to the cylinder head and tighten to 10 N·m (89 lb in) . |
3. | Install the camshaft housing. Refer to Camshaft Housing Installation . |
4. | Install the 2 timing belt rear cover bolts (2) to the camshaft housing (1) and tighten to 10 N·m (89 lb in) . |
5. | Install an engine lifter (1) to the right engine lift bracket and apply tension to the engine lifter chain in order to support the engine. |
6. | Remove the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4). |
7. | Remove the 2 engine mount to body bolts (2) and the engine mount nut (1). |
8. | Remove the engine mount (5). |
9. | Remove 3 engine mount bracket bolts (3). |
10. | Attach the 2 vacuum hoses (3) to the 2 vacuum regulator solenoid valves (2). |
11. | Install the vacuum hoses to 5 clips (1). |
12. | Install the camshaft timing pulley. Refer to Camshaft Timing Pulley Replacement . |
13. | Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement . |
14. | Install the 4 fuel injectors. Refer to Fuel Injector Replacement . |
15. | Install the fuel feed pipe from fuel pump to fuel rail. Refer to Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump . |
16. | Install the vacuum pump. Refer to Vacuum Pump Assembly Replacement . |
17. | Install the turbocharger with the exhaust manifold. Refer to Exhaust Manifold Replacement . |
18. | Filling the coolant system. Refer to Cooling System Draining and Filling . |