Cylinder head gasket (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. 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 head bolts.
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 dowels.
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. Fit h.t. lead guide brackets and secure with bolts.
12. Connect coil h.t. lead to distributor.
13. Fit bolt securing inlet manifold to support bracket and tighten to 25 Nm.
14. Connect multiplug to IACV.
15. Connect multiplug to TP sensor.
16. Connect multiplug to IAT sensor.
17. Connect injector harness multiplug and secure on throttle body mounting bracket.
18. Fit new ’O’ ring to fuel feed pipe
19. Fit fuel feed pipe to fuel rail and tighten bolts to 5 Nm.
20. Fit fuel return hose to fuel rail and secure with clip.
21. Secure fuel return pipe to clips on underside of inlet manifold.
22. Fit coolant pipe to inlet manifold and secure with clip.
23. Connect brake servo pipe to inlet manifold.
24. Connect ECM vacuum pipe to inlet manifold.
25. Fit evaporative emission canister vacuum pipe to inlet manifold and secure with clip.
26. Connect throttle cable to throttle cam.
27. Locate throttle cable adjusting nut in abutment bracket.
28. Connect coolant pipes to outlet elbow on cylinder head and secure with clips.
29. Connect multiplugs to coolant sensors on outlet elbow.
30. Fit camshaft timing belt rear cover and tighten bolts to 10 Nm.