Cylinder Head and Gasket Replace Opel Antara I



Cylinder Head and Gasket Replace

Tools Required

KM-470-B Angular Torque Gauge

DW110-060 Engine Assembly Support Fixture

Remove

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to Draining and Refilling the Cooling System .

5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replace .
6. Remove the engine beautification cover and the engine beautification cover bracket.
7. Disconnect the breather hose and PCV hose from the cylinder head cover.
8. Loosen the clamp and remove the resonator from the electronic throttle body.

9. Disconnect the Direct Ignition System (DIS) connector.
10. Disconnect the front heated oxygen sensor connector.
11. Disconnect the Electronic Throttle Control (ETC) connector.
12. Disconnect the Coolant Temperature Sensor (CTS) connector.
13. Disconnect the Exhaust Gas Recirculation (EGR) valve connector.

14. Remove the right front wheel.
15. Remove the engine front shield at the position of the right front wheel.
16. Remove the serpentine accessory drive belt. Refer to Accessory Drive Belt Replace .
17. Install the engine assembly support fixture DW110-060.
18. Remove the engine mount assembly. Refer to Engine Mount Assembly (LH Side) Replace .

19. Disconnect the upper radiator hose from the thermostat housing.

20. Remove the crankshaft pulley bolts.
21. Remove the crankshaft pulley.

22. Remove the front timing belt cover bolts.
23. Remove the front timing belt cover.
24. Remove the timing belt. Refer to Timing Belt Replace .

25. Remove the cylinder head cover and the gasket. Refer to Cylinder Head Cover Replace .

Important: Take extreme care to prevent any scratches, nicks or damage to the camshafts.

26. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolts.
27. Remove the intake camshaft gear.
28. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolts.
29. Remove the exhaust camshaft gear.

30. Remove the timing belt automatic tensioner bolts.
31. Remove the timing belt automatic tensioner.

32. Remove the timing belt idler pulley bolt and nut.
33. Remove the timing belt idler pulley.
34. Remove the engine mount adapter support bracket bolts.
35. Remove the engine mount adapter support bracket.

36. Remove the crankshaft gear.
37. Remove the camshaft position (CMP) sensor.

38. Remove the rear timing belt cover bolts.
39. Remove the rear timing belt cover.

40. Remove the primary catalytic converter-to-exhaust front pipe retaining nuts.
41. Remove the exhaust front pipe mounting bracket bolt and nut.
42. Remove the exhaust front pipe from the primary catalytic converter. Refer to Exhaust Front Pipe Replace .
43. Disconnect all of the necessary vacuum hoses.

44. Remove the intake manifold support bracket bolts and the bracket.
45. Remove the ground terminal retaining bolt from the intake manifold.

46. Disconnect the fuel feed line at the fuel rail.
47. Disconnect the coolant hoses at the rear cylinder head and the exhaust gas recirculation (EGR) valve adapter.
48. Disconnect the coolant hoses from the electronic throttle body.

49. Remove the fuel rail assembly. Refer to Fuel Rail and Injectors Replace .

50. Remove the alternator upper bracket bolts.
51. Remove the alternator upper bracket.
52. Remove the alternator-to-intake manifold strap bracket bolts on the alternator and the intake manifold.

53. Remove the evaporative (EVAP) emission canister purge solenoid valve bracket bolt.
54. Remove the EVAP emission canister purge solenoid valve.

55. Remove the camshaft. Refer to Camshafts Replace .
56. Loosen all of the cylinder head bolts gradually in the sequence shown.
57. Remove the cylinder head bolts.
58. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

Note: Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head.

59. Remove the cylinder head gasket.
60. Clean the gasket surfaces of the cylinder head and the engine block.
61. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
62. Clean the cylinder head bolts.
63. Inspect the cylinder head for warping. Refer to Cylinder Head and Valve Train Components Replace .

Install

Important: Before replacing the cylinder head, be sure to install the engine mount and then remove the engine assembly support fixture DW110-060.

1. Install the new cylinder head gasket.
2. Install the cylinder head with the intake manifold and the exhaust manifold attached.
3. Install the cylinder head bolts and tighten the cylinder head bolts gradually in the sequence shown.

Tighten

Tighten the cylinder head bolts to 25 N•m (18 lb-ft) and turn the bolts another 3 turns of 90° using the angular torque gauge KM-470-B.

4. Install the camshaft. Refer to Camshafts Replace .

5. Install the EVAP emission canister purge solenoid valve.

Tighten

Tighten the evaporative emission canister purge solenoid valve bracket bolt to 5 N•m (44 lb-in.).

6. Install the alternator upper bracket.

Tighten

Tighten the alternator upper bracket retaining bolts (1) to 25 N•m (18 lb-ft) and the bolt (2) to 35 Nm (26 lb-ft).

7. Install the alternator-to-intake manifold strap bracket.

Tighten

Tighten the alternator-to-intake manifold strap bracket retaining bolt (3) to 35 N•m (26 lb-ft) and the bolt (4) to 25 N•m (18 lb-ft).

8. Connect the coolant hoses to the electronic throttle body, rear cylinder head and the EGR valve bracket.
9. Install the fuel rail assembly. Refer to Fuel Rail and Injectors Replace .

10. Connect the fuel feed line at the fuel rail.
11. Connect all of the necessary vacuum hoses.

12. Install the ground terminal retaining bolt.
13. Install the intake manifold support bracket.

Tighten

Tighten the intake manifold support bracket bolts to 25 N•m (18 lb-ft).

14. Install the exhaust front pipe to the primary catalytic converter. Refer to Exhaust Front Pipe Replace .

Tighten

Tighten the primary catalytic converter-to-exhaust front pipe retaining nuts to 35 N•m (26 lb-ft).

Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N•m (30 lb-ft).

15. Install the rear timing belt cover.

Tighten

Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in.).

16. Install the engine mount adapter support bracket.

Tighten

Tighten the engine mount adapter support bracket retaining bolts to 45 N•m (33 lb-ft).

17. Install the timing belt idler pulleys.

Tighten

Tighten the timing belt idler pulleys retaining bolt and nut to 25 N•m (18 lb-ft).

18. Install the camshaft position sensor. Refer to Camshaft Position Sensor Replace .
19. Install the crankshaft gear.

Tighten

Tighten the crankshaft timing belt drive gear bolt to 135 N•m (100 lb-ft) and turn the bolt another 30° and 10° using the angular torque gauge.

20. Install the timing belt automatic tensioner.

Tighten

Tighten the timing belt automatic tensioner retaining bolt to 25 N•m (18 lb-ft).

21. Install the camshaft gears with the timing marks at the front.
22. Insert the guide pin of the intake camshaft into the "IN" bore.
23. Insert the guide pin of the exhaust camshaft into the "EX" bore.

24. Install the camshaft gears by counter holding on the hex of the camshaft with an open-ended wrench.
25. While holding the intake camshaft firmly in place, install a new intake camshaft gear bolt.

Tighten

Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60° and 15° using the angular torque gauge.

26. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft gear bolt.

Tighten

Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60° and 15° using the angular torque gauge.

27. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear cylinder head cover-to-cylinder head seal.
28. Install the cylinder head cover gasket and the cylinder head cover. Refer to Cylinder Head Cover Replace .

Tighten

Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).

29. Connect the ignition wires to the spark plugs.
30. Connect the breather hose and the PCV hose to the cylinder head cover.

31. Align the timing marks on the camshaft gears to the notches on the cylinder head cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.

32. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

33. Install the timing belt.
34. Check and adjust the timing belt tension. Refer to Timing Belt Check and Adjust .

35. Install the front timing belt cover.

Tighten

Tighten the front timing belt cover retaining bolts to 6 N•m (53 lb-in.).

36. Install the crankshaft pulley.

Tighten

Tighten the crankshaft pulley bolts to 23 N•m (17 lb-ft).

37. Install the engine mount assembly. Refer to Engine Mount Assembly (LH Side) Replace .

Tighten

Tighten the engine mount adapter bolts to 50 N•m (11 lb-ft).

Tighten the engine mount frame side bracket bolt to 100 N•m (74 lb-ft) and nuts to 90 N•m (66 lb-ft).

38. Remove the engine assembly support fixture DW110-060.
39. Install the serpentine accessory drive belt. Refer to Accessory Drive Belt Replace .
40. Connect the upper radiator hose to the thermostat housing.

41. Install the engine front shield at the position of right front wheel.
42. Install the right front wheel.
43. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replace .

Tighten

Tighten the air cleaner housing bolts to 10 N•m (89 lb-in.).

44. Connect the IAT sensor connector.

45. Connect the CTS sensor connector.
46. Connect the ETC sensor connector.
47. Connect the DIS coil connector.
48. Connect the O2 sensor connector.
49. Connect the EGR valve connector.

50. Install the fuel pump fuse.
51. Connect the negative battery cable.
52. Refill the engine cooling system. Refer to Draining and Refilling the Cooling System .