| In-vehicle Repair Special Tool(s) | | Guide Studs, Cylinder Head 303-034 | | | Gauge, Bolt Angle 303-174 | Materials Name Specification Silicone Sealant
WSE-M4G323-A4 | | -
Remove the exhaust manifold.
For additional information, refer to: Exhaust Manifold (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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Remove the thermostat.
For additional information, refer to: Thermostat (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
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Remove the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump - 1.6L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation).
| 5. Remove the components in the order indicated in the following illustration(s) and table(s). 6. To install, reverse the removal procedure. Removal Details Item 1 : Camshaft housing retaining studs and bolts | | -
Remove the camshaft housing retaining studs and bolts in the sequence shown. | Item 3 : Cylinder head bolts | | -
CAUTION:Do not remove the cylinder head bolts until the cylinder head has cooled to below 30°C. Remove the cylinder head bolts in the sequence shown. - Discard the cylinder head bolts.
| Installation Details Item 5 : Cylinder head gasket | | -
CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked). CAUTION:Make sure that the two locating dowels are installed. NOTE:Install a new cylinder head gasket. Install the cylinder head gasket. - Locating dowels.
- Cylinder head gasket tooth.
| Item 3 : Cylinder head bolts | | -
NOTE:Install new cylinder head bolts. Install the cylinder head. - Using the special tool, tighten the cylinder head bolts in the sequence shown in three stages.
| Item 2 : Camshaft housing | | -
CAUTION:Install the camshaft housing within five minutes of applying the sealant. Apply a 2.5 mm diameter bead of sealant to the mating face of the cylinder head. | | | -
Using the special tool, align the camshaft housing to the cylinder head. | Item 1 : Camshaft housing retaining studs and bolts | | -
Install the camshaft housing retaining studs and bolts. - Tighten the camshaft housing retaining studs and bolts in two stages in the sequence shown.
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