Cylinder head gasket - LH (page 4 of 4)

Refit

1. Clean manifold flange mating faces.
2. Thoroughly clean cylinder block and cylinder head mating faces.
3. Thoroughly clean cylinder head bolts and wipe dry.
4. Lightly lubricate threads and under heads of bolts with clean engine oil.
5. Ensure locating dowels are in cylinder block.
6. Fit new cylinder head gasket onto cylinder block with word ’TOP’ uppermost.
7. Fit new gasket to exhaust manifold flange.
8. Using assistance, fit cylinder head, carefully locating front manifold to rear manifold flange and cylinder head to dowels.
9. Carefully enter cylinder head bolts, DO NOT DROP. Screw bolts into place by hand.

10. Tighten cylinder head bolts progressively in sequence shown to 25 Nm. Tighten bolts in sequence shown a further 90°.
11. Clean mating surfaces of camshaft cover and carrier.
12. Clean inside of camshaft cover. If necessary, wash oil separator gauze and blow dry.

CAUTION: When fitting new camshaft cover gasket ensure arrows point towards inlet manifold.

13. Fit gasket and position camshaft cover to carrier. Fit bolts and tighten progressively in sequence shown to 9 Nm.
14. Fit manifold nuts and tighten to 45 Nm.
15. Fit bleed hose and secure with clips.
16. Remove and discard lower ’O’ rings from injectors.
17. Clean injectors and injector locations in fuel rail.
18. Lubricate new ’O’ rings with clean engine oil and fit to injectors.
19. Position fuel rail assembly, connect inlet air temperature sensor, secure injectors to manifolds. Fit bolts securing fuel rail and tighten to 9 Nm.
20. Secure harness clip to engine lifting bracket.
21. Position harness bracket to camshaft cover, fit bolt and tighten to 9 Nm.
22. Connect camshaft sensor, coolant temperature sensor and oxygen sensor multiplugs.
23. Secure fuel pipes to clips.
24. Fit bolt securing fuel return pipe to inlet manifold and tighten to 9 Nm .
25. Position expansion tank pipe, connect bleed hoses to ’T’ piece and secure with clips.
26. Connect coil multiplugs, align mounting plate to manifold, fit bolts and tighten to 9 Nm.
27. Fit breather hoses to camshaft cover.
28. Connect h.t. leads to spark plugs and secure leads to clips.
29. Clean timing cover backplate bolts and apply Loctite 242 to first 3 threads.
30. Ensure seal is fitted correctly to timing cover backplate. Position backplate, fit bolts and tighten to 9 Nm.
31. Clean and thoroughly dry timing gear and hub.
32. Fit timing gear and hub and fit bolt. Tighten bolt sufficiently to allow gear to rotate without tipping.
33. Fit camshaft timing belt. See this section.
34. Refill cooling system. See COOLING SYSTEM - ’KV6’, Adjustments.