Installation

1. Thoroughly clean all the flanges and install new gaskets. Use a few drops of gasket sealant or the like to hold the gasket onto the inlet manifold flange.





2. Lift the cylinder head onto the block, ensuring that it is properly seated in the locating pins and that the timing chain has not become trapped.





3. Install the 10 cylinder head bolts, tightening them in three stages and in the sequence shown:

Tightening Sequence For Head Bolts:

^ Stage I 40 Nm ( 30 ft. lbs. )
^ Stage II 60 Nm ( 44 ft. lbs. )
^ Stage III Tighten a further quarter-turn (through 90°)





4. From underneath, install the two bolts securing the timing cover to the cylinder head.
5. Check that the camshafts are lined up with their respective timing marks and that the '0' mark on the flywheel is in line with the timing mark on the end plate.





6. Install the camshaft sprockets (exhaust side first) leaving the center-bolts slack. Check that the chain is correctly seated on the sprocket teeth and in the guides. To facilitate alignment, leave some slack in the chain between the sprockets.








7. Unscrew the chain-tensioner plug and remove it complete with spring and plastic guide pin. Cock and install the tensioner to 65 Nm (52 ft. lbs.). Install the guide pin and spring, followed by the screw plug to 22 Nm (16 ft. lbs.).





8. Tighten the center-bolts in the camshaft sprockets to 65 Nm (48 ft. lbs.).





9. Rotate the crankshaft two complete turns and check that the timing marks on the camshafts and flywheel are still in alignment.





10. Install the two bolts in the top of the engine mounting bracket and tighten the lower ones at the same time.





11. Tighten the bolts securing the lower part of the inlet manifold to the cylinder head and to the steady bars.








12. Install the top half of the inlet manifold complete with dipstick-tube bracket. Install the bolts holding the two halves of the inlet manifold together.








13. Install the split rubber plugs in the cylinder head. Apply beads of silicone sealant in the places shown.Install the camshaft cover.





14. Reconnect the crankcase-breather and vacuum hoses.
15. Reconnect the preheater hoses to the throttle housing and install the throttle-position sensor.
16. Reconnect the throttle cable to the linkage (Automatics: and the kickdown cable).








17. Install the ignition module (cartridge). Clip the lead to the pressure-sensor bracket.





18. Install the fuel-pressure regulator complete with bracket and hoses onto the cylinder head. Remember to reconnect the earth lead from the ignition module.
19. Plug on the temperature-sensor connector.





20. Reconnect the hose from the heater box to the thermostat housing, and the top coolant hose to the cylinder head.








21. Install the rubber elbow and air mass meter assembly between the throttle housing and air-intake silencer. Plug in the air mass meter connector.








22. Using a new gasket, install the exhaust manifold.
23. Install the belt-tensioner bracket onto the cylinder head.





24. Install the bracket for the AC compressor.





25. Install the compressor, and plug on the connector.





26. Install the drive belt.





27. Reconnect the earth lead from the torque arm to the cylinder head.





28. Install the torque arm. Secure the hoses and wiring to the torque arm using new ties.
29. Raise the car and install the fender liner. Install the wheel and torque the bolts to 130 Nm (96 ft. lbs.).








30. Check that the radiator drain plug is screwed in tight and lower the car. Replenish the coolant.





31. Reconnect the battery.
32. Run the engine up to normal temperature. Check the coolant level and top up as necessary. Make sure there are no leaks.