Cylinder head gasket, replacement

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1 "VCC EN " 1(7) Cylinder head gasket, replacement Special tools: Disconnect battery earth lead Drain coolant Remove heat shield over exhaust manifold. (Only the two bottom bolts on the plate need be removed.) Remove expansion tank cap. Drain coolant through cock on righthand side of cylinder block. Fit tube to cock to facilitate collection of coolant. Remove tube and close drain cock on completion of drainage. Strip righthand side of cylinder head Unbolt exhaust pipe from bracket. Remove manifold nuts. Detach manifold from cylinder block. Strip lefthand side of cylinder head Remove support under intake manifold. Remove bottom bolt in cylinder block. Detach and tie up manifold in suitable manner. Disconnect temperature sensor connectors. Disconnect heating hose under No. 3 and 4 cylinder intake

2 "VCC EN " 2(7) branches. Disconnect upper coolant hose at thermostat. Strip front and top of cylinder head Carry out operations K1 Camshafts and tappets, replacement K14. Separate camshaft carrier from cylinder head Remove four remaining nuts from central bolted joint. Detach carrier from head. Tap carrier carefully with plastic mallet if component is stuck to head. Remove Orings around spark plug wells. Remove cylinder head Wipe remaining oil from cylinder head. Undo bolts in order shown, commencing at rear of engine. Remove cylinder head and gasket. Caution! Cylinder head is made of aluminium. Place on pair of clean wooden blocks or similar supports to avoid scoring.

3 "VCC EN " 3(7) Clean and inspect all cylinder head joint faces See operation M2 Camshaft carrier/cylinder head joint, resealing regarding cleaning of camshaft carrier and removal of sealing compound. Clean and inspect cylinder block joint faces. Clean and inspect cylinder head bolts Bolts should be replaced if any evidence of elongation is observed. (This will be indicated by thinning of midsection.) Bolts should be used no more than 5 times. Replace bolts if in any doubt regarding above. Fit: new cylinder head gasket new Oring seal for water pump

4 "VCC EN " 4(7) Place cylinder head in position Lower head carefully into position over guides, taking care to avoid damaging gasket. Tighten cylinder head bolts Use protractor Oil bolts. Insert and tighten bolts in three stages, in order shown. 1 = 20±2 Nm (15±1.5 ft. lb) 2 = 40±5 Nm (30±4 ft.lb) 3 = Tighten through further 115 ±10. Install exhaust manifold Use new gasket. Place manifold in position. Replace and install nuts. Bolt lifting lug in position between No. 2 and 3 exhaust branches. Reattach front exhaust pipe to bracket. Install bottom heat shield.

5 "VCC EN " 5(7) Reconnect: temperature sensor connectors heating hose under No. 3 and 4 cylinder intake branches upper coolant hose to thermostat. Caution! Note marking on hose. Clearance between hose and alternator drive belt must be at least 25 mm (1 in). Fill cooling system Check system for leaks. Install intake manifold Use new gasket. Screw in bottom bolts a few turns. Place intake manifold and lifting lugs in position. Tighten manifold from centre outwards.

6 "VCC EN " 6(7) Reattach support under intake manifold Install cable clip. Check connections on and underneath manifold. Apply liquid sealing compound Apply compound to joint between camshaft carrier and cylinder head, and to bearing cap joint faces (1, 5 and 6). Apply compound with a shorthaired roller. Note! Remove excess compound from oilways prior to reassembly. Install camshaft carrier Fit new Orings in grooves around spark plug wells. Position carrier on cylinder head and replace nuts 1, 2, 4 and 5 in central bolted joint.

7 "VCC EN " 7(7) Insert tappets and install camshafts as described in operations K17 Camshafts and tappets, replacement K20 (Liquid sealing compound has already been applied to camshaft bearing caps.) Tighten five nuts on camshaft carrier and all bearing caps Tighten five nuts in central bolted joint and on all bearing caps. Tighten to 20 Nm (15 ft.lb). Carry out operations K22 Camshafts and tappets, replacement 26 and F12 Camshaft seals, replacement K24.

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