All engines (page 5 of 5)

59. Fit cylinder liner clamps 18G 1736/1 to cylinder block and secure with cylinder head bolts.

CAUTION: Do not rotate crankshaft with cylinder head removed.

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.
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: Take care not to damage HO2S 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 realign radial marks.

10. Fit camshaft cover. See this section.
11. Connect h.t. leads to distributor cap.
12. Connect expansion tank hose to inlet manifold and tighten 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 plugs from fuel system hoses and components.
20. Connect hose to fuel return pipe and secure with clip.
21. Clean union of fuel filter and fuel outlet pipe.