GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Engine 🢒 Engine Mechanical - 1.8L (L79) 🢒 Cylinder Head Disassemble

Tools Required

    • J 8062 (KM 348) Valve Spring Compressor - Head Off
    • KM-653-A Adapter

Disassembly Procedure

    Object Number: 1289841 Size: SH
  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement .
  2. Remove the exhaust manifold heat shield bolts.
  3. Remove the exhaust manifold heat shield.
  4. Remove the exhaust manifold retaining nuts in the sequence shown.
  5. Remove the exhaust manifold.
  6. Remove the exhaust manifold gasket.
  7. Remove the exhaust manifold studs.

    8. Object Number: 1289846 Size: SH
  8. Remove the thermostat housing mounting bolts.
  9. Remove the thermostat housing assembly.
  10. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  11. Remove the coolant bypass housing mounting bolts and the housing.

    12. Object Number: 1289837 Size: SH
  12. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
  13. Remove the intake manifold.
  14. Remove the intake manifold gasket.

    15. Object Number: 1289863 Size: SH
  15. Remove the direct ignition system (DIS) coil and the exhaust gas recirculation (EGR) mounting bracket bolts.
  16. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
  17. Remove the intake manifold studs.
  18. Remove the spark plugs.

    19. Object Number: 1289787 Size: SH
  19. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.

    20. Object Number: 1289868 Size: SH
  20. Remove the intake camshaft caps. Maintain the correct positions for installation.
  21. Remove the intake camshaft.
  22. Remove the intake valve tappet adjusters.
  23. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
  24. Remove the exhaust camshaft.
  25. Remove the exhaust valve tappet adjusters.

    26. Object Number: 1289869 Size: SH

    Caution: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.

  26. Compress the valve springs with J 8062  (1) and the KM-653-A  (2).
  27. Remove the valve retainers.
  28. Remove the J 8062  (1) and the KM-653-A  (2).
  29. Remove the valve spring caps.
  30. Remove the valve springs. Maintain the original position of the valve springs for installation.

    31. Object Number: 1289870 Size: SH
  31. Remove the valves. Maintain the original position of the valves for installation.
  32. Remove the valve stem seals.