All engines (page 6 of 6)

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. Connect air intake pipe to throttle body and secure with clip.
20. Remove plugs from fuel system hoses and components.
21. Connect fuel return pipe to fuel rail and secure with clip.
22. Fit new ’O’ ring to fuel feed pipe.
23. Connect fuel feed pipe to fuel rail and secure with bolts. Tighten bolts to 5 Nm.
24. Connect multiplug to IACV.
25. Connect HO2S multiplug to engine harness and secure to clip on bracket.
26. Secure coil h.t. lead to clip on bracket and connect to distributor cap.
27. Connect multiplug to IAT sensor.
28. Connect multiplug to injector harness.
29. Connect multiplug to TP sensor.
30. Connect multiplugs to ECT sensors.
31. Connect coolant hose to coolant outlet elbow and tighten clip.
32. Connect radiator top hose to coolant outlet elbow and tighten clip.
33. Fit new gasket to exhaust manifold flange and connect exhaust front pipe.
34. Fit 4 nuts securing exhaust front pipe to exhaust manifold and tighten to 45 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 cylinder block and tighten bolts to 10 Nm.
37. Fit 2 camshaft gears to their respective camshafts.

38. Fit bolts and washers securing camshaft gears to camshafts. Using tool 12-182 restrain camshaft gears and tighten bolts to: M8 Bolts - 35 Nm. M10 Bolts - 65 Nm
39. Using tool 12-182 align camshaft gear timing marks and fit camshaft gear locking tool 18G 1570.