Installation

1. Thoroughly clean all the flanges and fit new gaskets. Use a few drops of gaskets sealant or the like to hold the gasket on the intake manifold flange.

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







3. Install the 10 torx bolts and using the sequence shown, tighten them in three stages:
Stage I: 60 Nm (44 ft. lbs.).
Stage II: 80 Nm (59 ft. lbs.).
Stage III: tighten a further quarter-turn (90°).


4. Install the two bolts securing the timing cover to the cylinder head and tighten to: 22 Nm (16 ft. lbs.).

5. Check that the camshafts are in line with their timing marks and that the 0° mark on the crankshaft is in line with the timing mark.

6. Install the camshaft sprockets and chain.
- Start with the camshaft on the inlet side.
- Do not tighten the bolts yet.

7. Prepare the chain tensioner for installing by pressing down the catch and pushing in the chain tensioner.







8. Install the chain tensioner, using a 27 mm socket, then tighten to: 63 Nm (47 ft. lbs.).

9. Install the plug for the chain tensioner with push rod and spring, then tighten to: 22 Nm (16 ft. lbs.).

10. Check that the chain is correctly seated in the guides.
- Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment.

11. Tighten the camshaft sprocket bolts to: 63 Nm (47 ft. lbs.).






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







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







14. Fit the top of the intake manifold complete with the dipstick -tube bracket.







15. Fit the split rubber plugs in the cylinder head. Apply beads of silicone sealant in the places shown.







16. Fit the camshaft cover. Then tighten the bolt located furthest to the front at the timing end. Then continue all the way round, on both the inside and outside, tighten to: 15 Nm (11 ft. lbs.).







17. Reconnect the crankcase-breather and vacuum hoses.

18. Reconnect the preheater hoses to the throttle housing and fit the throttle position sensor.







19. Reconnect the throttle cable to the linkage (Automatics: and the kickdown cable).







20. Fit the ignition module (cartridge). Clip the lead to the pressure-sensor bracket.

21. Fit the fuel-pressure regulator complete with bracket and hoses onto the cylinder head. Remember to reconnect the earth lead from the ignition module.







22. Reconnect the connector for the temperature sensor.







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

24. Reconnect plug on the air mass connector.







25. Using a new gasket, refit the exhaust manifold.

26. Fit the belt-tensioner bracket onto the cylinder head.







26. Fit the bracket for the A/C compressor.







27. Fit the compressor, and plug in the connector.







28. Fit the drive belt.







29. Reconnect the ground lead from the torque arm to the cylinder head.







30. Fit the torque arm. Secure the hoses and wiring to the torque arm using new ties.

31. Raise the car and fit the splash guard. Refit the wheel and torque bolts to: 130 Nm (96 ft. lbs)






32. Check that the radiator drain plug is screwed in tight and lower the car.

33. Refill coolant.

34. Reconnect the battery.

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