Refit

any tight threads using M11 x 1.5 mm tap. Remove all traces of oil from bolt holes.

Refit

1. Fit location dowels to cylinder block.
2. Fit new gasket, dry, to cylinder block.
3. Fit cylinder head.
4. Apply a light film of engine oil to bolt threads and underside of bolt heads. Fit bolts finger tight.

5. Working in the sequence shown, tighten cylinder head bolts progressively in three stages:
   Stage 1 = 45 Nm
   Stage 2 = 80 Nm
   Stage 3 = a further 90°, using an angular torque gauge.
6. Fit inlet and exhaust camshaft covers, tighten bolts to 10 Nm.
7. Fit timing belt to camshaft gears, see MAINTENANCE.
8. Connect exhaust front pipe to manifold, see MANIFOLD & EXHAUST – Repairs.
9. Remove stand(s) and lower vehicle.
10. Position engine harness over camshaft covers.
11. Position harness and fuel return hose brackets to inlet manifold, fit and tighten bolts.
12. Connect fuel return hose to pressure regulator and secure with clip.
13. Remove sealing plugs, connect fuel hose to fuel filter and, using 2 spanners, tighten union to 38 Nm.
14. Connect coil H.T. lead to distributor cap.
15. Connect injector harness multiplug.
16. Connect fuel and inlet air temperature sensor multiplugs.
17. Position throttle housing on inlet manifold studs and tighten nuts to 8 Nm.
18. Naturally aspirated models: Connect breather hose to inlet camshaft cover and secure with clip.
19. Position brake servo hose and sealing washers to inlet manifold, fit and tighten banjo bolt to 50 Nm.
20. Connect vacuum hose to inlet manifold and secure with clip.
21. Connect E.C.U. pressure sensing hose to inlet manifold.
22. Connect intake air hose to thermostat housing and tighten clip.
23. Connect oxygen sensor flylead and secure multiplug to clip.
24. Fit dipstick tube.
25. Position coolant rail and expansion tank rail.
26. Position coolant rail to cylinder head, fit and tighten nut and bolt.
27. Align expansion tank rail to coolant rail and cylinder head, fit and tighten bolts.

Turbo models

28. Fit exhaust manifold and turbocharger, see MANIFOLD & EXHAUST – Repairs.
29. Fit alternator, see ELECTRICAL – Repairs.
30. Fit intercooler, see MODULAR ENGINE MANAGEMENT SYSTEM – Repairs
31. Connect camshaft sensor multiplug.
32. Connect harness to coolant thermistor and temperature gauge sensor.
33. Air conditioning: Connect hose to outlet elbow, tighten clip to 3.5 Nm.
34. Non air conditioning: Connect hose to thermostat housing, tighten clip.

All models

35. Refill cooling system, see MAINTENANCE.
36. Fit air cleaner, see MODULAR ENGINE MANAGEMENT SYSTEM – Repairs – MPi.
37. Connect battery earth lead.
38. Check engine oil level and top – up if necessary see MAINTENANCE..
39. Start engine and check for leaks.

Note: If tappet noise is evident, run engine for 20 minutes at 2000 to 2500 rev/min. Do not exceed 3000 rev/min until noise ceases.

40. Stop engine and allow to cool; top – up coolant level if necessary, see MAINTENANCE.