Inspection

34. Working in the sequence shown, progressively loosen 10 cylinder head bolts.
35. Remove cylinder head bolts and store in fitted order.
36. Using assistance, remove cylinder head from engine and place on blocks or stands to prevent damaging valves.
37. Remove and discard cylinder head gasket.

38. Remove location dowels from cylinder block.

Inspection

39. Inspect cylinder head for damage, cracks and burning.
40. Inspect cylinder block. Ensure oil restrictor is clear and fitted below block face.
41. Clean all traces of gasket material from head and block mating faces, using release agent and plastic scraper.
42. Check cylinder head and block faces for warpage: Longitudinal warp = 0.1 mm max. Transverse warp = 0.1 mm max. Diagonal warp = 0.1 mm max.
43. Decarbonise cylinder head and pistons if necessary.
44. Clean cylinder head bolt threads with a wire brush, check for damage, replace if necessary.

Refit

1. Fit location dowels to cylinder block.
2. Fit NEW gasket to cylinder block.

NOTE: Fit NEW gasket dry.

3. With assistance, fit cylinder head to block location dowels.
4. Apply a light film of engine oil to bolt threads and underside of bolt heads, fit bolts finger tight.

5. Working in sequence shown, progressively tighten the cylinder head bolts using the following procedure. i. All bolts to 45 Nm. ii. All bolts to 80 Nm. iii. Turn all bolts through 90° using an angular torque wrench.
6. Position h.t. leads to spark plugs and secure.
7. Fit exhaust camshaft cover. See this section.
8. Fit inlet camshaft cover. See this section.
9. Connect fuel return hose to fuel rail and secure clip.
10. Align fuel return pipe to inlet manifold, fit bolts and tighten to 10 Nm.
11. Connect brake servo vacuum pipe to inlet manifold.
12. Connect multiplug to FT sensor.
13. Connect fuel pipe to fuel filter and tighten union to 30 Nm.

CAUTION: To prevent damage to fuel pipes or components, use 2 spanners when loosening or tightening unions.