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Cylinder head cover - removal and refitting
In-car engine repair procedures / Cylinder head cover - removal and refitting


1 Unplug the two electrical connectors and disconnect the vacuum hose (where fitted), then remove the air cleaner assembly cover with the air mass meter, the resonator and the plenum chamber (see Chapter 4).

2 Disconnect the accelerator cable from the throttle linkage as described in Chapter 4.

Where fitted, disconnect also the cruise control actuator cable (see Chapter 12).

3 Remove the timing belt upper cover (see Section 9).

4 Disconnect the crankcase breather hose from the cylinder head cover union (see illustration).

5.4 Disconnecting crankcase breather hose from cylinder head cover union
5.4 Disconnecting crankcase breather hose from cylinder head cover union

5 Unplug the HT leads from the spark plugs and withdraw them, unclipping the leads from the cover.

6 Working progressively, unscrew the cylinder head cover retaining bolts, noting the spacer sleeve and rubber seal at each, then withdraw the cover (see illustration).

5.6 Removing cylinder head cover
5.6 Removing cylinder head cover

7 Discard the cover gasket; this must be renewed whenever it is disturbed. Check that the sealing faces are undamaged, and that the rubber seal at each retaining bolt is serviceable; renew any worn or damaged seals.

8 On refitting, clean the cover and cylinder head gasket faces carefully, then fit a new gasket to the cover, ensuring that it locates correctly in the cover grooves (see illustration).

5.8 Ensure gasket is located correctly in cover groove
5.8 Ensure gasket is located correctly in cover groove

9 Refit the cover to the cylinder head, then insert the rubber seal and spacer sleeve at each bolt location (see illustration). Start all bolts finger-tight, ensuring that the gasket remains seated in its groove.

5.9 Ensure rubber seal is fitted to each cover bolt spacer, as shown
5.9 Ensure rubber seal is fitted to each cover bolt spacer, as shown

10 Working in a diagonal sequence from the centre outwards, and in two stages (see Specifications), tighten the cover bolts to the specified torque wrench setting.

11 Refit the HT leads, clipping them into place so that they are correctly routed; each is numbered, and can also be identified by the numbering on its respective coil terminal.

12 Reconnect the crankcase breather hose, and refit the timing belt upper cover.

Reconnect and adjust the accelerator cable, then refit the air cleaner assembly cover with the air mass meter, the resonator and the plenum chamber (see Chapter 4).


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