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

6.   Release camshaft adjuster Hall-effect sensors •   Disconnect 2 wiring harness plugs (1) •   Unscrew 4x bolts (2)

7.   Remove camshaft adjuster Hall-effect sensors (2) •   Rotate camshaft adjuster Hall-effect sensors as shown in the graphic – Rotate intake side to the left – Rotate exhaust side to the right •   Remove camshaft adjuster Hall-effect sensors •   Remove camshaft adjuster Hall-effect sensor seal ring (1)

10.   Drain coolant •   Place collecting basin underneath. •   Push on suitable hose (2) •   Open drain cock (1) in the direction of the arrow •   Collect coolant •   Close drain cock

Important:   When removing the centre silencer, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured against uncontrolled sagging. Bends in the flex pipe by as little as 5 - 10 angle degrees or a twist through ± 0.5 ° from the specified installation position can lead to damage with subsequent complete failure of the flex pipe. The exhaust system fastening clamps must be replaced every time they are removed. When replacing the exhaust system, the transport fixing must first be removed after installation and before commissioning. This should be stored for other work in which the exhaust system must be removed and used to secure the flex pipe. 11.   Attach transport fixing to flex pipe. Note:   The installation instruction (1) on the transport fixing must be observed.

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

14.   Remove ribbed V-belts from alternator and compressor Note:   For vehicles with climate control system. •   Mark direction of rotation •   Tension the ribbed V-belt tensioner using EN-48488 (1) in the direction of the arrow •   Insert KM-955-2 (2) •   Relieve tension on ribbed V-belt tensioner

21.   Loosen coolant lines (1) •   Unclip from 3 brackets (2), (3) and (4) •   Rotate bracket (2) by 90°

22.   Detach engine damping block support from timing case •   Unscrew 2x bolts Important:   Ensure that the chassis paint is not damaged. •   Insert rags (1) •   Route the extension through the coolant lines (arrow)

23.   Loosen lower engine damping block support •   Unscrew bolt (1) •   Take out support upwards

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

26.   Slacken timing case •   Unscrew 5x bolts, coolant pump (1) •   Unscrew 6x timing case bolt (2)

33.   Remove cylinder block base plate locking screw (2) with seal ring (1)

34.   Adjust TDC of combustion stroke of cylinder 1 •   Marking on the crankshaft belt pulley marker bore (2) must align with the cast projection (1) on the timing case •   Turn crankshaft evenly until KM-952 engages •   Insert KM-952 (3) to the stop.

35.   Remove closure bolt of chain tensioner (1) from timing case

36.   Lock chain tensioner (2) using KM-955-1 (3) -- to do this, tension the intake camshaft via the hexagon and using the open-end spanner (1) in the direction of engine rotation (direction of arrow)

37.   Detach upper sliding rail (2) from cylinder head •   Unscrew 2x bolts (1)

38.   Detach camshaft sprockets •   Counterhold with open-ended wrench against the hexagon of the camshafts •   Unscrew 2x bolts (4) •   Remove phase sensor discs (3) •   Pull camshaft sprockets (2) from camshafts •   Set aside camshaft sprockets (2) with timing chain (1) in timing case and secure with cable tie

39.   Remove cylinder head bolts Note:   Undo cylinder head bolts in the order shown. •   Slacken 12x bolts, 90° •   Slacken 12x bolts 180° 40.   Remove cylinder head Note:   Use a second person. •   Draw chain tensioner past the tension rail •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

41.   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)

43.   Check cylinder head and cylinder block with a straightedge Note:   Before carrying out the check, carefully remove any old gasket residues from the cylinder head sealing surface and the cylinder block surface. Do not use any metal, sharp-edged tools when cleaning. Ensure that the cylinder head sealing surface and the cylinder block surface are not damaged. •   Sealing surface for bend, lengthways and widthways •   Check sealing surface for distortion in the diagonal

  Install

45.   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. •   Place new cylinder head gasket on cylinder block – With TOP/OBEN marking at the top •   Apply a bead of silicone sealing compound approx. 2 mm thick in the corner between the timing case/cylinder block •   Press on in the area of the silicone sealing compound

46.   Adjust timing case gasket to fit at the top (1) •   Insert 2x bolt, timing case (arrows) •   Position new part gasket 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)

48.   Fasten cylinder head Important:   Use new bolts. •   Screw in cylinder head bolts a few thread turns •   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 Important:   Note correct tightening sequence. •   Tighten 12 cylinder head bolts 35 Nm + 180°

51.   Lower engine Important:   Ensure that the chassis paint is not damaged. •   Insert a plastic or wood wedge (1) between the chassis and the engine damping block support

52.   Loosen lower engine damping block support •   Unscrew bolt (1)

54.   Detach engine damping block support from timing case •   Unscrew 2x bolts Important:   Ensure that the chassis paint is not damaged. •   Insert rags (1) •   Route the extension through the coolant lines (arrow) •   Take out support upwards

55.   Fasten timing case •   Release lower 3 bolts (screws fitted beforehand) from cylinder head again •   Install coolant pump bolts – Tighten 5x bolt (1) 8 Nm •   Install timing case bolts – Tighten 6x bolt (2), (5) and (8) 8 Nm •   Attach camshaft sensor (3) and (7) with new seal ring – Tighten bolt (4) and (6) 8 Nm

59.   Apply / attach locating tool EN-49977-200 (2) •   The teeth of the locating tool (1) must engage in the teeth of the intake camshaft sprocket Note:   Press locating tool in direction of arrow to ensure that it engages without play.

60.   Tighten locating tool EN-49977-200 •   Press locating tool in direction of arrow •   Tighten 2x fastening bolt (1) •   Tighten adjusting bolt (2)

61.   Attach locating tool EN-49977-100 (1) •   Turn phase sensor discs in such a way that EN-49977-100 (1) can be inserted on the timing case •   Tighten 3x fastening bolt Note:   It is possible that the tool has been applied in the wrong position. Ensure that there is no play between the fixing tool and the cylinder head at points (2) and (3).

70.   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.

88.   Insert camshaft adjuster Hall-effect sensors (2) •   Insert camshaft adjuster Hall-effect sensor seal ring (1) •   Screw in camshaft adjuster Hall-effect sensors

89.   Tighten camshaft adjuster Hall-effect sensors •   Screw in 4x bolt (2) – Tightening torque 8 Nm . •   Connect 2x wiring harness plug (1)

91.	Install air cleaner housing

95.	Fill and bleed cooling system