Workshop Manual, TPD 1350, issue 3
39
12
New 1000 Series
Cylinder head assembly
(Engine types AJ to AS and YG to YK)
To remove and to fit
12-7
To remove
1 Drain the cooling system.
2 Disconnect the battery terminals.
3 Remove the air filter/cleaner hose at the induction
manifold.
4 For engines fitted with turbochargers: Remove the
air filter/cleaner hose at the compressor inlet of the
turbocharger.
5 Remove the pipe which is fitted between the fuelled
starting aid in the induction manifold and the fuel filter.
Disconnect the electrical connection.
6 For engines fitted with a boost control device:
Remove the boost control pipe which is fitted between
the induction manifold and the top of the fuel injection
pump.
7 Remove the induction manifold.
For induction manifolds fitted to engine types AR and
AS: The top half of the induction manifold (A1) is
sealed to the bottom half (A2) with a liquid joint and
fastened together by six cap screws.
The top half of the manifold must be removed to
obtain access to four of the manifold fasteners (A3),
fitted inside the manifold. These fasteners retain the
bottom half of the manifold to the cylinder head.
8 For engines fitted with turbochargers: Disconnect
all connections to the turbocharger and remove the
turbocharger
, see operation 18-1
.
9 Release the exhaust manifold fasteners in the
reverse sequence to that shown in (B). The front of
the engine is shown at (B1).
10 Remove the low-pressure fuel pipes which are
fitted between the fuel injection pump and the fuel
filter.
Note: Where a Bosch fuel injection pump is fitted,
keep the fuel outlet banjo bolt with the fuel injection
pump.
Remove the fuel pipe fitted between the fuel lift pump
and the fuel filter. Remove the fuel filter bracket
together with the fuel filter.
Caution: Where access to the fuel injection pump
outlet unions is possible, ensure that a separate
spanner is used to prevent movement of the fuel
injection pump outlets when the connections of the
high-pressure pipes are released. Fit suitable covers
to all open connections on the fuel injection pump.
11 Remove the high-pressure fuel pipes.
Continued
3
2
1
A
A0403
1
B
9
18
17
18
16
9
7
6
4
1
3
10
12
13
15
8
5
2
11
14
17
8
5
2
11
14
16 9
7
6
4
1
3
10
12 13
15
8
5
2
11
4
3
12
7
6
1
10
A1444
Purchased from www.WorkshopManuals.co.uk
Summary of Contents for New 1000 Series
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