All engines (page 5 of 5)

Refit

1. Remove bolts securing cylinder liner clamps to cylinder block and remove clamps.
2. Clean joint surfaces of cylinder head and cylinder block. Clean oil and coolant passages. Clean mating face of exhaust manifold and exhaust front pipe. If necessary, de-carbonise piston crowns and cylinder head.
3. Clean cylinder head bolts with a wire brush. Inspect cylinder head bolts for signs of damage. See this section.
4. Wash cylinder head bolts and wipe dry. Apply a light film of oil to bolt threads and underside of bolt heads.
5. Clean location dowels and fit to cylinder block.
6. Fit NEW cylinder head gasket, dry, to cylinder block.
7. Using assistance, fit cylinder head onto cylinder block carefully locating on dowels.

CAUTION: Never shuffle head from side to side to align dowels. If necessary, lift head off and try again.

CAUTION: Take care not to damage heated oxygen sensor when refitting cylinder head.

8. Carefully enter cylinder head bolts, DO NOT DROP. Screw bolts into place by hand.

9. Working in the sequence shown, progressively tighten the cylinder head bolts using the following procedure. i. All bolts to 20 Nm. Use a felt tip pen and mark position of radial mark on each bolt head. ii. Turn all bolts through 180°. iii.Turn all bolts through another 180° and align radial mark.

CAUTION: If bolt is overtightened, back off 90° then re-align radial marks.

10. Fit camshaft cover. See this section.
11. Position distributor cap, fit and tighten screws.
12. Connect expansion tank hose to inlet manifold and secure clip.
13. Connect vacuum hose to inlet manifold.
14. Secure throttle cable to clip on inlet manifold, ensure throttle cable is correctly routed.
15. Connect brake servo vacuum hose to inlet manifold.
16. Connect throttle cable to throttle cam.
17. Locate throttle cable adjusting nut in abutment bracket.
18. Connect purge hose to throttle housing and secure with clip.
19. Remove plug from fuel system hose.
20. Connect fuel feed pipe to manifold.
21. Connect multiplug to idle air control valve.
22. Connect heated oxygen sensor multiplug to engine harness and secure to clip on bracket.
23. Connect multiplug to intake air temperature sensor.
24. Connect multiplug to injector harness.
25. Connect multiplug to throttle position sensor.
26. Connect multiplugs to engine coolant temperature sensors.
27. Connect coolant hose to coolant outlet elbow and secure clip.
28. Connect radiator top hose to coolant outlet elbow and secure clip.
29. Position coil bracket, fit and tighten bolts to 25 Nm.
30. Connect coil HT lead to distributor.
31. Fit NEW gasket to exhaust manifold flange and connect exhaust front pipe.
32. Fit 4 nuts securing exhaust front pipe to exhaust manifold and tighten to 45 Nm.
33. Fit 2 bolts securing exhaust front pipe to sump and tighten to 25 Nm.
34. Fit 2 nuts securing exhaust front pipe to IRD housing and tighten to 25 Nm.
35. Fit camshaft timing belt rear cover to cylinder head and cylinder block.
36. Fit 4 bolts securing camshaft timing belt rear cover to cylinder head and tighten bolts to 9 Nm.
37. Fit 2 camshaft gears to their respective camshafts.