Alloy and plastic inlet manifold

55. Release injector harness multiplug from bracket, disconnect multiplug.
56. Disconnect multiplug from air temperature sensor.

57. Slacken clips, disconnect 2 coolant hoses from cylinder head.
58. Disconnect 2 multiplugs from coolant sensors.
59. Disconnect ht lead from distributor cap.

Alloy and plastic inlet manifold

60. Slacken 10 cylinder head to oil rail bolts in sequence shown. Remove bolts and store in fitted order.
61. Remove cylinder head assembly from cylinder block, use assistance.
62. Remove cylinder head gasket from cylinder block and discard.

CAUTION: Do not rotate crankshaft with cylinder head removed.

Refit

1. Clean joint surfaces on cylinder head and block.
   Clean oil and coolant passages.
   Clean exhaust manifold and front pipe joint surfaces.
2. De-carbonise piston crowns and cylinder head if necessary.
3. Inspect cylinder head bolts, see Cylinder Head Bolts Inspection.
4. Wash cylinder head bolts and wipe dry. Oil threads and under head of bolts.
5. Fit new cylinder head gasket onto cylinder block.
6. Fit cylinder head onto cylinder block carefully locating dowels, use assistance.
7. Carefully enter cylinder head bolts, DO NOT DROP. Screw bolts into place by hand.

7. Tighten cylinder head bolts progressively in sequence shown, using the following procedure:
   1. All bolts to 20 Nm. Use a felt tip pen and mark position of radial mark on each bolt head.
   2. Turn all bolts through 180°
   3. Turn all bolts through another 180° and align mark.

CAUTION: If bolt is overtightened, back off 90° and realign.

Alloy inlet manifold

8. Align and fit support stays to inlet manifold and manifold chamber, tighten bolts to 25 Nm.
9. Connect multiplugs to coolant sensors.
10. Connect h.t. lead to distributor cap.
11. Using new washers, connect brake servo hose banjo to manifold and tighten to 50 Nm.
12. Connect 2 coolant hoses to cylinder head, tighten clips.
13. Connect expansion tank hose to inlet manifold, tighten clip.
14. Position engine harness around inlet manifold, secure with clips.
15. Connect multiplugs to injectors.
16. Connect multiplug to intake air temperature sensor.
17. Connect multiplug to throttle potentiometer.
18. Connect multiplug to stepper motor.
19. Connect throttle inner cable to throttle cam.
20. Adjust throttle cable, see MODULAR ENGINE MANAGEMENT SYSTEM – Adjustments – MPi.
21. Connect vacuum hoses to inlet manifold.