Remove and Refit

Remove
- Disconnect battery ground cable and drain coolant from system.
- Remove both air cleaner elements and covers.
- Remove ignition amplifier.
- Remove both intake manifolds and gaskets.
- Remove both camshaft covers and gaskets. Remove left side fender brace.
- Disconnect fuel return hose from fuel cooler and position fuel cooler aside.
- Disconnect spark plug lead wires from spark plugs.
- Disconnect top hoses from the thermostat housings and water rails.
- Loosen clips securing coolant cross pipe hose to water rail.
- Remove bolts securing water rail.
- Remove engine lifting eyes and disconnect water rails and gaskets from coolant cross pipe and remove rail.
- Disconnect camshaft oil feed pipe from cylinder head.
- Remove exhaust manifold heat shield, and engine dipstick and tube assembly.
- Raise front of vehicle and support with suitable stands.
- Working from under the vehicle, remove left side down pipe heat shield and disconnect pipe from exhaust manifold. Remove rear manifold lower securing nuts.
- Lower vehicle and remove rear exhaust manifold. Loosen fan belt and remove fan/clutch assembly from pulley, position aside.
- Disconnect expansion hose from coolant filler pipe neck.
- Rotate engine using crankshaft pulley nut and position camshaft 180° BTDC.
- Bend back tab washers and loosen accessible camshaft sprocket retaining bolts.

Fig. 1 Valve timing gauge installed:

- Rotate engine until valve timing gauge C3993 can be fitted.
- Bend back tab washers and loosen remaining camshaft sprocket bolts.

Fig. 2 Retracting timing chain tensioner.:

- Remove rubber grommet from front timing chain cover and using tool JD 50 release tension on timing chain.
- Remove camshaft sprocket retaining bolts and tab washers.

CAUTION: Do not rotate engine again until camshaft sprockets are refitted to camshafts.

Fig. 3 Retaining tool installation.:

- Place sprocket onto chain guide and retain using tool JD 40, or equivalent.
- Starting at the center and working outward remove cylinder head nuts.

NOTE: Over time, the head(s) can become stuck to the 11/16in SAE head studs. This is caused by corrosion and electrolysis between the stud and the head.
When attempting to separate the head from the block, be careful NOT to damage the sealing surfaces. If the head is stuck, apply a good penetrating fluid to each stud. Fit common nuts (11/16in SAE) to each stud and carefully jar the nuts with an air hammer from different angles. This procedure MUST be performed VERY CAUTIOUSLY. Carelessness can result in damage to the head or bending the stud. Continue applying penetrant and vibrating the studs until each stud moves freely within the head. Carefully pry the head upward.

- Remove cylinder head and gasket.

Refit
- Be sure that the cylinder heads and block mating faces are clean and all oil/water galleries are not obstructed.
- Fit a new gasket to the LH cylinder block, ensuring that the side marked 'TOP' is uppermost.

CAUTION: Do not use any grease or jointing compound on the cylinder head gasket. The head surface and the head gasket can be painted with dull aluminum spray paint to improve sealing.

- Fit the cylinder head.
- Fit the cylinder head securing nuts and washers. Tighten the cylinder head to block securing nuts in the correct sequence to:

9/16"AF 36Nm (26.5 ft lb)
5/8"AF 70Nm (52 ft lb)


- Tighten the cylinder head to timing cover securing nuts to the torque figures given below.
- Remove JD 40 from the LH camshaft sprocket and check the alignment of the sprocket retaining bolt holes.
- If the camshaft and sprocket holes are not in alignment, remove the coupling to sprocket retaining circlip and disengage the coupling from the splines, at the same time pressing the sprocket on to the camshaft shoulder.
- Rotate the coupling until alignment is obtained.
- Engage the splines, and fit two securing bolts using a new tab washer.
- Lock over the tabs and refit the retaining circlip.
- Remove Timing Gauge C 3993.

CAUTION: Do not rotate engine unless both camshafts are secured to their gears.

- Rotate the engine until the remaining sprocket securing bolts/tab washers can be fitted.
- Tighten the bolts and lock over the tabs.
- Refit the camshaft oil feed pipe assembly using new sealing washers.
- Refit the amplifier unit.
- Remove the banking plugs and reconnect the fuel hoses to the cooler.
- Refit the exhaust manifold heat shields.
- Refit the transmission dipstick tube.
- Refit the exhaust down pipes, using new sealing rings.
- Refit the heat shields.
- Refit the steering rack gaiter heat shield.
- Fit JD 50 (Chain Tension Retainer) and raise the timing chain tensioner slightly.
- Insert JD 50 (Release Tool) through the timing cover. Release the locking catch and allow the tensioner to expand.
- Remove both Service Tools.
- Refit the rubber grommet to the front of the timing cover.
- Refit the compressor and drive belt.
- Refit the air pump/auxiliary pulley adjusting bolt bracket. Adjust the pulley and tighten the locknuts.
- Refit the fan & clutch assembly. Be sure that the paint marks align.
- Refit the thermostat housing/air valve assembly, using new gaskets.
- Reconnect the crossover pipe hose to the thermostat housing.
- Apply sealant to the radial edge of a new half moon seal and fit the seal to the rear of the cam carrier.
- Fit new cam cover gasket.
- Fit cam cover and torque tighten the securing nuts/bolts.
- Refit the induction manifolds.
- Evacuate and charge the air conditioning system.
- Refit the air cleaner.
- Reconnect the battery.
- Check/top up the engine oil.