Cylinder head - removal and refitting (engine in vehicle)
Note: Refer to the warning in Section 8 and the note at the beginning of Section 21 before proceeding.
1 Disconnect the battery negative lead.
2 Drain the cooling system.
3 Disconnect the coolant hose from the thermostat housing.
4 Disconnect the wiring from the temperature gauge sender.
5 Disconnect the HT leads from the spark plugs and from the clips on the camshaft cover and remove the spark plugs.
6 On carburettor models, remove the air cleaner.
7 The cylinder head can be removed either with or without the manifolds. If desired, the inlet manifold can be unbolted and moved to one side, leaving the wires, hoses, pipes and cables connected, but care must be taken not to strain any of the wires, hoses, pipes or cables.
8 Unscrew the three securing nuts and disconnect the exhaust downpipe from the manifold flange. Recover the gasket.
9 Disconnect the coolant hose from the clip on the exhaust manifold hot air shroud, and if desired, remove the exhaust manifold.
10 If the inlet manifold is to be removed with the cylinder head, disconnect all relevant wires, hoses, pipes and cables, otherwise, unbolt the manifold and move it to one side, ensuring that it is adequately supported.
11 If not already done, unclip any wires and hoses from the camshaft cover, noting their locations for use when refitting, and on fuel injection models unbolt the bracing strut securing the inlet manifold to the right-hand side of the cylinder head.
12 If desired, remove the thermostat and housing, and the temperature gauge sender.
13 Proceed as described in Section 21 for cylinder head removal.
14 With the cylinder head refitted as described in Section 21, proceed as follows.
15 Where applicable, refit the temperature gauge sender and the thermostat and housing.
16 Refit the manifolds and/or reconnect all wires, hoses, pipes and cables, as applicable.
17 Reconnect the exhaust downpipe to the manifold, using a new gasket.
18 Refit the coolant hose to the clip on the exhaust manifold hot air shroud.
19 Refit the spark plugs and reconnect the HT leads.
20 Reconnect the temperature gauge sender wiring.
21 Reconnect the coolant hoses to the thermostat housing.
22 Fill the cooling system.
23 If not already done, refit any hoses and wires to the camshaft cover, as noted during removal, and on fuel injection models refit the inlet manifold bracing strut. If splined type cylinder head bolts have been used, leave these operations until the bolts have been finally tightened after running the engine.
24 Refit the air cleaner on carburettor models.
25 Reconnect the battery negative lead.
26 If splined type cylinder head bolts have been used, start the engine and run it at 1000 rpm for 15 minutes, then stop the engine, remove the air cleaner and the camshaft cover as described previously, and finally tighten the cylinder head bolts to the fourth stage (see Specifications). Refit the camshaft cover on completion, then refit any hoses and wires, and on fuel injection models the inlet manifold bracing strut. Refit the air cleaner.
Seat belts - removal and refitting
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Locks and Security
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Suspension and steering
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