4.5.5. Removal and installation of a head of cylinders

Start work performance only after full cooling of the engine!

Removal

L engines 1.4 and 1.6

 PERFORMANCE ORDER

  1. Uncover GRM (see the Section Removal and installation of a cover of the gas-distributing mechanism).
  2. Separate the socket a lambda probe and remove it from the holder on the transmission.
  3. Turn out bolts of fastening and disconnect a reception pipe at a final collector and at a connecting flange to the catalytic converter.
  4. Remove a starter (see the Head Sistemy of electric equipment of the engine).
  5. Give two bolts of fastening of the pulse sensor near a camshaft cogwheel.
  6. Turn out bolts of fastening of cogwheels of camshafts for what hold shaft from a provorachivaniye a wrench for inflow of the first cylinder.

Keeping of camshafts at a reversing of bolts of fastening of cogwheels

  1. Turn out the top bolts of fastening of a back cover of a gear belt.

Top bolts of fastening of a back cover of a gear belt

  1. Turn out bolts of fastening and shoot both intermediate videos of a gear belt from a head of cylinders.
  2. Weaken all bolts of fastening of a head of cylinders in the order designated on an accompanying illustration.

Order of an otdavaniye of fixture of a head of cylinders

Weakening of bolts of fastening of a head of cylinders is allowed to be made only on the cooled-down engine.

  1. Remove a head of cylinders with the inlet pipeline and a final collector.

L engines 1.0 and 1.2

Further removal and installation of a head of cylinders of the three-cylinder DOHC engine of 1.0 l is described. For the DOHC engine of 1.2 l with four cylinders it is necessary to work similarly. Special instructions are provided in appropriate places.


 PERFORMANCE ORDER

  1. Pit fuel pressure (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  2. Disconnect a negative wire from the battery.
  3. Remove the air filter with the MAF sensor, a sleeve of an air inlet and a hose of ventilation of a case (PCV).
  4. Merge motive oil (see the Head Nastroyki and routine maintenance of the car).
  5. Merge cooling liquid (see the Head Nastroyki and routine maintenance of the car).
  6. Disconnect the top and lower hoses from a radiator.
  7. Separate the socket of an electrical wiring of the sensor of pressure of oil, ECT and CMP sensors.
  8. Turn out the CMP sensor from the GRM case.
  9. Disconnect hoses from the water pump.
  10. Separate the socket step э / the motor and a potentiometer of a butterfly valve.
  11. Remove a cable of a butterfly valve and the holder.
  12. Disconnect all hoses of the cooling system, a vacuum hose and a hose of PCV from the case of a butterfly valve.
  13. Separate the multicontact socket of the dashboard (lower).

Not later than 20 with disconnect the battery before.

  1. Remove the control valve of the evaporator with the holder.
  2. Press fuel hoses clips and disconnect them from the holder.
  3. Disconnect a vacuum hose of the amplifier of brakes about a final collector.
  4. Remove the back holder of an electrical wiring from the inlet pipeline.
  5. Turn out the top bolt of a support of the inlet pipeline, weaken the lower bolt of a support.
  6. Remove the lower holder of an electrical wiring from the inlet pipeline.
  7. Disconnect the contact tire of injectors, pull up and take aside.
  8. Give bolts of fastening of a pulley of the water pump.
  9. Take off a belt of the drive of auxiliary units.
  10. Remove a pulley of the water pump.
  11. Turn out the lower drain stopper from the water pump and collect the following liquid in suitable capacity.
  12. Disconnect hoses from a broad tank of the cooling system.
  13. Remove the tank from a partition of a motive compartment.
  14. Uncover a head of cylinders.
  15. Turn out 3 bolts of fastening and uncover the thermostat case.
  16. Install the piston of the first cylinder in the provision of VMT (see the Section of the Procedure of repair of petrol DOHC engines without their extraction from the car).

The provision of a bent shaft corresponding to the situation close to VMT is necessary in order that it was possible to implant a lock finger of a bent shaft easily.

  1. In the specified situation camshaft cams, managing directors of gas distribution in the first cylinder watch (section 1-1) outside under the same corner.

Orientation of cams at installation of the piston of the first cylinder in the provision of VMT

  1. Turn out a stopper (1) under a lock finger of a bent shaft.

Stopper (1) under a lock finger of a bent shaft

  1. Implant a lock finger of a bent shaft (1) (KM-952) into an opening of a plate of the block of cylinders and evenly and slowly turn a bent shaft for the central bolt in the direction of rotation of the engine so that the lock finger entered a groove of a bent shaft. At the same time the bent shaft is in the provision of VMT of the piston of the first cylinder.

Devices for fixing of cranked (1) and distributive (2) shaft

  1. Fix the camshaft special KM-953 (2) adaptation in the provision of VMT (address an illustration).

If there is no tool (KM-954) for fixing of a washer of the CMP sensor, mark with a chertilka the provision of a cogwheel of the camshaft of inlet valves in relation to the GRM case and the provision of a washer of the sensor of phases in relation to a camshaft cogwheel.

  1. Turn out the directing tube of the probe of measurement of level of oil and take out it upward.
  2. Separate the socket a lambda probe.
  3. At the corresponding complete set separate the К/В compressor socket.
  4. Turn out bolts of fastening and disconnect the catalytic converter from a final collector. Take out sealing laying.
  5. At the corresponding complete set turn out bolts of fastening and disconnect the K/V compressor from the GRM case.

Do not open a contour of cooling К/В. The coolant which is in it can lead to a frostbite.

  1. Turn out bolts of fastening and remove lock levels of the engine over a final collector.
  2. Turn out bolts of fastening and remove the top thermofilter of a final collector.
  3. Uncover an oil filter (1).

Cover and case of an oil filter

Close the catalytic converter that on it oil at removal of the case of an oil filter did not drip.

  1. Remove the case of an oil filter (2) from the block of cylinders (shooter) (address an illustration). Enclose more rags for collecting the following oil.
  2. Separate the socket of the AGR (1) valve and the sensor of temperature (3).

Socket of the AGR (1) sensor, sensor of temperature (3) and union of a contour of cooling (2)

  1. Disconnect a hose of the cooling system (2) from the AGR valve case (address an illustration).
  2. Turn out a stopper from an opening of a natyazhitel of a chain (shooter).

Stopper of a natyazhitel of a chain of the GRM drive and the fixing core (2)

  1. Wring out a natyazhitel of a chain the screw-driver back and record a suitable core (2) (address an illustration). For this purpose it is possible to use KM-955 adaptation.
  2. Remove a pro-rate (1).

Pro-rate (1) and lock finger of a natyazhitel of a chain (2)

  1. Weaken fastening of asterisks of camshafts. For this purpose hold camshafts a wrench for a hexagon around cams of management of gas distribution of the first cylinder.

The lock tool for camshafts is not intended for deduction of shaft.

  1. Remove asterisks with a CMP sensor washer from camshafts and throw off from them a chain.
  2. Suspend a chain on the GRM case so that it could not fall in the case.
  3. Turn out bolts of fastening of the case of the GRM drive.

Bolts of fastening of the case of the GRM drive

  1. Remove the tool for fixing of camshafts.
  2. Give bolts of fastening of a head of cylinders to the sequences with 1 on 10 at first on a quarter of a turn, then half way and then turn out them completely.

Order of an otdavaniye of bolts of fastening of a head of cylinders

  1. On the engine of 1.2 l of DOHC give bolts of fastening of a head of cylinders to the sequences with 1 on 12 as it is described above. At the same time begin with the top left bolt (bolt (2)) (on an illustration) and then give other bolts, moving on a spiral counterclockwise.
  2. Wring out a head of cylinders towards the transmission and remove a head from the block of cylinders.

The lock pin for a natyazhitel of a chain needs to be directed through an opening in the GRM case.

  1. Lay a head of cylinders on two wooden supports not to damage valves.
  2. Remove sealing laying of a head of cylinders (1).

Sealing laying of a head of cylinders

  1. Unbend laying of the case of the mechanism of distribution in points of a separation (arrow) and cut through working edges of laying in the center (address an illustration). You watch that did not remain any of working edges of sealing laying of a head of cylinders.
  2. Remove all laying and the remains of laying.

Preparation for installation

See the Section Removal and installation of a head of cylinders.

Installation

L engines 1.4 and 1.6

 PERFORMANCE ORDER

  1. Clear a shaber the interfaced surface of the block of cylinders of the sealant remains. You watch that dirt did not get to openings of the block. Close openings pure rags.

Carving openings of bolts of fastening of a head of cylinders have to be cleared of oil and cooling liquid. Blow openings compressed air or remove liquid by means of the screw-driver with the rags which are reeled up on it. Otherwise at a vvorachivaniye of new bolts in the block cracks can be formed, and values of effort of tightening will be distorted.

  1. Check a curvature of the interfaced surface of the block of cylinders (see the Part the General and capital repairs of the engine of the present Chapter).
  2. Put new sealing laying without sealant on the fat-free interfaced surface of the block of cylinders a surface. Laying has to be laid so that at the same time any of openings was not closed. The inscription "OBEN/TOP" on laying has to be turned up and towards a gear belt of the engine.
  3. Clear the interfaced surface of a head of cylinders.
  4. Check a curvature of the interfaced surface of a head of cylinders (see the Part the General and capital repairs of the engine of the present Chapter).
  5. Establish a head of cylinders and evenly tighten to a prileganiye new bolts of fastening in the order designated on an accompanying illustration.

Order of tightening of bolts of fastening of a head of cylinders

Surely apply new bolts of fastening.

  1. Bolts have to drag on in five receptions: at first tighten them with effort of 25 Nanometers, then - tighten them on a corner the 90th hail three times., and in conclusion, tighten bolts on a corner the 45th hail.
  2. Tighten bolts of fastening of a back top cover of a gear belt with effort of 6 Nanometers.
  3. Establish cogwheels of camshafts, holding a shaft from a provorachivaniye for inflow by a wrench. Tighten a new bolt of fastening of the camshaft with effort of 65 Nanometers.

Surely apply new bolts of fastening.

  1. Establish a cover of a head of cylinders and tighten bolts of its fastening cross-wise with effort of 8 Nanometers.
  2. Establish a starter (see the Head Sistemy of electric equipment of the engine).
  3. Fix a reception pipe of system of release on a collector with effort of 25 Nanometers and on a connecting flange of the catalytic converter with effort of 18 Nanometers.
  4. Establish a gear belt (see the Section Removal and installation of a belt of the GRM drive (l engines 1.4 and 1.6)).
  5. Establish a forward cover of a gear belt.
  6. Tighten with effort 4 Nanometers fixture of a cover of VV of wires.
  7. Further installation is made as it should be, the return to an order of dismantle of components.
  8. Fill the cooling system (see the Section the General information), and also check and, if necessary, modify oil level in the engine. If the head of cylinders was removed owing to damage of sealing laying, replace oil and the filter since in oil there can be a cooling liquid.

L engines 1.0 and 1.2

 PERFORMANCE ORDER

  1. Clear the interfaced surfaces of the block of cylinders and the GRM case of the sealant remains. You watch that dirt did not get to openings of the block of cylinders.

Carving openings of bolts of fastening of a head of cylinders have to be cleared of oil and cooling liquid. Blow openings compressed air or remove liquid by means of the screw-driver with the rags which are reeled up on it. Otherwise at a vvorachivaniye of new bolts in the block cracks can be formed, and values of effort of tightening will be distorted.

  1. Clear the interfaced surface of a head of cylinders.
  2. Check a curvature of a head of cylinders (see the Part the General and capital repairs of the engine of the present Chapter).

It is not allowed to grind a head of cylinders.

  1. Cut off ledges of new sealing laying of a head of cylinders (size I) on the party of the case of the GRM drive.

Places of a cut and tag of top of sealing laying of a head of cylinders

  1. Install asterisks of camshafts with the chain which is put on them in the GRM case.
  2. Apply rollers (1) of silicone sealant 2 mm thick on corners of the case of the drive of the GRM/block of cylinders.

Putting sealant (1) on a GRM drive cover joint with a head of cylinders and bolts of fastening of the case of the GRM drive

Apply only OPEL, ET No. 90 543 772 sealant. After putting sealant the head of cylinders and the GRM case have to be established and tightened by bolts within 10 min.

  1. Establish new sealing laying of a head of cylinders so that it was not blocked any of openings. The inscription "OBEN/TOP" on laying has to be turned up. Press laying around silicone sealant.
  2. Insert both top bolts (2) fastenings of the case of the GRM drive at the left and on the right (address an illustration).
  3. Hang above sealing laying by openings at the left and on the right on bolts, and press it below, around the applied silicone sealant.
  4. Put two other rollers in corners of the GRM case and laying of a head of cylinders.
  5. Insert clamps of camshafts. If the clamp does not approach, slowly turn shaft for a hexagon.
  6. Install a head of cylinders on the block. At the same time you watch that the lock finger for a natyazhitel of a chain passed through an opening in the case of the GRM drive and a natyazhitel of a chain by a tension level.
  7. Press a head of cylinders to the GRM drive case.
  8. Screw 3 lower bolts of fastening of a head of cylinders to the case of the GRM drive and tighten them with effort of 8 Nanometers.

The lower bolts of fastening of a head of cylinders to the GRM drive case

  1. Once again easy blows of the plastic hammer correct the provision of a head of cylinders in the direction of the GRM case.
  2. Remove a clamp of camshafts.
  3. Insert new bolts of fastening of a head of cylinders and tighten them to a prileganiye to a head of cylinders. Then tighten bolts of fastening of a head of cylinders for four inclusion in the sequences with 1 on 10: at first - with effort of 25 Nanometers, and then - tighten them on a corner the 60th hail three times.

Order of tightening of bolts of fastening of a head of cylinders

  1. On the DOHC engine of 1.2 l tighten bolts of fastening of a head of cylinders in the sequence with 1 on 12 also for four receptions. At the same time begin tightening with the central bolt in the top number of bolts and continue, moving in the direction clockwise. Thus the bolt at the left above (a bolt (8) (on an illustration) drags on the last.
  2. Again give 3 lower bolts of fastening of a head of cylinders to the GRM drive case.
  3. Tighten at first bolts of fastening (1) of the water pump to a head of cylinders with effort of 8 Nanometers, and then bolts (2) cases of the GRM drive to a head of cylinders with effort of 8 Nanometers.

Bolts of fastening of the water pump (1) and case of the GRM (2) drive to a head of cylinders

  1. Establish a clamp of camshafts. If the clamp does not approach, slowly turn camshafts for a hexagon.
  2. Install asterisks with a chain on camshafts.

If the conductor of a rotor is not present the CMP sensor, establish an asterisk so that the tag put at removal coincided with the GRM case.

  1. Press a CMP sensor rotor to an asterisk of the inlet camshaft and slightly fix an asterisk by a new bolt. Tighten a bolt so that the CMP sensor rotor still could rotate.
  2. Tighten also slightly a bolt of fastening of an asterisk of the final camshaft.
  3. Insert the top pro-rate and fix it with effort of 8 Nanometers.
  4. Take out a clamp of a natyazhitel of a chain.
  5. Establish the conductor (1) of a rotor of the CMP (KM-954) sensor and fix it on the GRM case. If necessary turn a CMP sensor rotor so that it was possible to establish the conductor.

Conductor of a rotor of the CMP sensor

If there is no conductor of a rotor of the CMP sensor, turn a rotor so that the tag put before removal coincided with a tag on a camshaft asterisk. At the same time the tag on an asterisk of the camshaft has to coincide with the GRM case. In this situation tighten a bolt of fastening of an asterisk of the camshaft. At the same time you watch that the rotor of the CMP sensor did not rotate relatively to a camshaft asterisk.

  1. Tighten bolts of fastening of asterisks of camshafts with effort of 50 Nanometers and tighten bolts on a corner the 60th hail. At the same time hold the camshaft from a provorachivaniye a wrench for a hexagon.

Mandrels for fixing are not allowed to be applied as the tool to deduction.

  1. Remove all lock mandrels and check gas distribution phases. For this purpose turn a bent shaft on 2 turns in the direction of rotation of the engine and stop in the provision of VMT of the piston of the first cylinder. If in this situation lock mandrels are inserted at the same time and without problems, adjustment of phases of distribution is executed truly.
  2. Tighten an opening stopper for a natyazhitel of a chain with effort of 20 Nanometers.
  3. Install the CMP sensor with a new sealing ring on the GRM case.
  4. Tighten an opening stopper for a stopper of a bent shaft with effort of 60 Nanometers.
  5. Put on a cooling system hose the AGR case and fix it by a collar.
  6. Connect sockets of the AGR valve and the sensor of temperature.
  7. Install on the block of cylinders the case of an oil filter with a new sealing ring and tighten its fixture with effort of 20 Nanometers. Fix on the case a cover with a new sealing ring.
  8. Install the top thermofilter of a final collector and tighten its fixture with effort of 8 Nanometers.
  9. Establish lock levels of the engine and tighten their fixture with effort of 20 Nanometers.
  10. At the corresponding complete set install the K/V compressor on the GRM case and the block of cylinders and tighten its fixture with effort of 20 Nanometers.
  11. Fix by hand the catalytic converter with new consolidation on a final collector, without tightening fastening bolts.
  12. Screw by hand, without tightening, bolts of fastening of the holder of the catalytic converter.
  13. Install the catalytic converter and tighten its fixture with effort of 35 Nanometers, and the holder's fixture - with effort of 15 Nanometers.
  14. At the corresponding complete set connect the socket of the K/V compressor on the holder.
  15. Establish the directing pipe of the probe of level of motive oil with new laying and tighten its fixture to a final collector with effort of 8 Nanometers.
  16. Further installation is made in the sequence, the return sequence of dismantle of components. Tighten fixture with the required effort.
  17. In conclusion of installation fill the cooling system, and also check and, if necessary, modify oil level in the engine. If the engine was removed owing to damage of sealing laying of a head of cylinders, replace oil and an oil filter since in motive oil there can be a cooling liquid.