Refit

8RM 1559

36. Remove bolts and special washers.
37. Lift off cylinder head together with manifolds.
38. Remove and discard gasket.
39. Check that 2 locating dowels are in position in cylinder block.
40. Remove oil control jet and 'O' ring; discard 'O' ring.

Refit

1. Thoroughly clean cylinder head and cylinder block mating surfaces.
2. Ensure locating dowels are in cylinder block.
3. Fit a new 'O' ring; fit oil control jet in cylinder block.
4. Position new gasket on cylinder block.

CAUTION: Gasket must be fitted dry.

5. Ensure 'UP' mark on camshaft pulley is at the top (T.D.C.) position.
6. Using assistance, carefully lower cylinder head on to cylinder block ensuring that dowels are correctly located in head.
7. Ensure cylinder head bolts are clean.
8. Apply clean engine oil to each cylinder head bolt and to the special washers.
9. Fit each cylinder head bolt and special washer and tighten finger tight only.
10. Working in the order shown, tighten each cylinder head bolt in two stages:
    Stage 1 to 30 Nm
    Stage 2 to 65 Nm
11. Fit and tension camshaft timing belt.
12. Connect exhaust front pipe, see MANIFOLD & EXHAUST – Repairs.
13. Position wiring harness to fuel rail and inlet manifold.
14. Connect 4 multiplugs to injectors.
15. Fit 2 nuts and bolt to secure cover and harness; tighten nuts and bolt to 22 Nm.
16. Fit 2 bolts securing inlet manifold to support bracket; tighten bolts to 22 Nm.
17. Connect fast idle multiplug.
18. Secure multiplug to bracket on inlet manifold.
19. Manual gearbox: Connect 2 reverse lamp switch leads.
20. Connect 2 distributor multiplugs.
21. Secure distributor multiplugs in retaining clips.
22. Connect multiplug to throttle angle sensor.
23. Connect T.A. sensor multiplug to inlet manifold.
24. Connect 2 coolant sensor multiplugs at cylinder head.
25. Connect air cleaner and MAP sensor hoses to inlet manifold.
26. Connect P.C.V. hose to inlet manifold.
27. Connect thermostat housing to inlet manifold hose; locate 2 clips.
28. Connect heater hoses tighten clip.
29. Connect top hose; tighten clip.
30. Automatic gearbox: Connect throttle control cable to lever.
31. Automatic gearbox: Tighten nut on throttle control cable.
32. Connect throttle cable and tighten locknut.
33. Connect fuel return hose to fuel rail; tighten clip.
34. Connect fuel outlet pipe to fuel filter; use new sealing washers.
35. Connect brake servo hose to inlet manifold; tighten clip.
36. Fit camshaft cover, see Camshaft cover gasket.

8RM 1560