EM.

2-1

Cylinder head

page

Disassembly figures for cylinder head...........................................EM.2-2

Dismantle of cylinder head...........................................................EM.2-3

Disassembly of cylinder head ......................................... .............EM.2-4

Clean up /inspection on each spare part ......................... .............EM.2-5

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Assembly of cylinder head.........................................................EM.2-12

Installation of cylinder head........................................................EM.2-15

EM.2-2 Disassembly figures for cylinder head

To prevent the cylinder gasket from leaking air or water, the tightening torque of bolts on cylinder head shall
be checked using a torque wrench before new vehicles travel for 500 or1000 kilometers, and will be 90N.m for
ten M12 bolts, or 20N.m for three M8 bolts. And a tightening may not proceed until the engine cools down. To
perform a correct maintenance and adjustment, a general description is provided as below for dismantle /
inspection /maintenance of cylinder head.

Disassembly figures for cylinder head

valve locker
clamp

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valve spring
valve chamber cover valve spring upper seat (air
seat air exhaust inlet)
valve spring
rocker shaft and spring
valve oil seal
rocker shaft valve spring
lower seat

valve
spark plug
push rod
engine
spark plug sleeve
valve guide

engine rear fender

cylinder head
water outlet pipe

front warm-air cylinder gasket

water pipe

hydraulic tappet
engine front
engine hook fender
Dismantle of cylinder head EM.2-3

Dismantle of cylinder head

1. Dismantle of high-tension damping wiring andignition
coil components
(a)High-tension damping wiring shall be removed.
(b)Ignition coil components shall be removed.
2. Dismantle of wiring harness and the fuel distributor
assembly
(a)Wiring harness must be removed.
(b)Unscrew the contact nut.
(c)Take out the fuel distributor assembly.

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3. Piston for cylinder No. 1 will be placed to thetopdead
center of compression stroke.
Rotate the crankshaft pulley to have its groove facing exactly to mark
0 made on the timing chaincover.

4. Dismantle of inlet &outlet manifold

(a)Have the cooling-water bypass hose removed from theinlet manifold.
(b)A torque wrench will be used to unscrew eight fixing nutson inlet
&outlet manifold, based on which the inlet &outlet manifold plus the
sealing ring may be taken out.
EM.2-4 Disassembly of cylinder head

5. Dismantle of cylinder head

The cylinder head may be removed by unscrewing the bolts and nuts on
cylinder head.

6. Dismantle of rocker-shaft
Subject to the numbering sequence indicated in the figure, bolts and nuts
on rocker-shaft may be removed progressively in three steps.

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7. Dismantle of cylinder head
(a)Based on the bolt numbering sequence indicated inthe figure, a 12-edge
socket spanner shall be used tounscrew bolts on cylinder head
progressively in threesteps. Any dismantle in nonconformance with
theindicated sequence might cause a deformation or bendon cylinder
head.
(b)The cylinder head may be lift up from the connection surface of
device unit, and put onto a wood block onsaddle piece which has been
provided in advance.
Note Do not damage cylinder head, and the sur face of
device unit on one side having cylinder-cover spacer.
R emark If the cylinder head is hard to be lifted up, a screwdriver may
be used to prize the middle of convexity on cylinder head.
(c) Sealing ring will be removed from the cylinder head.

Disassembly of cylinder head

1. Dismantle of rear fender from cylinder head
Rear fender and sealing ring may be removed from the cylinderhead by
unscrewing four bolts.

engine rear fender

2. Dismantle of cooling-water outlet pipe

Cooling-water outlet pipe and sealing ring may be removed by unscrewing
two bolts.
 Cleanup /inspection on each spare part EM.2-5

3. Dismantle of the rocker-shaft assembly

Based on the numbering sequence indicated in the figure, bolts and nuts
on rocker shaft maybe unscrewed progressively in two or three steps to
prevent the rocker-shaft from bending or prevent bolts from damage.

4. Dismantle of valve
(a)Valve spring seat will be compressed using SST until two valve locker
clamps have been removed.
SST 09202-43013
(b)SST and two valve locker clamps shall be removed.
(c) Take out valve spring seat, valve spring, and spring shim successively.
(d) Remove the oil-seal.

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(e) Disassembly the valve.

(f) Disassembly other valves in a similar way.

(g) Place all removed parts in a good order.

IN

EX

Cleanup /inspection on each spare part

1. Clean the top of piston and device unit
(a)Carbon deposits on the top of piston may be scraped awaywhen the
piston inside each cylinder has been lifted respectively to the upper stop
point while the crankshaft isrotating.
(b)All spacer materials must be cleared away from the top of device unit,
and carbon deposits and oil contaminants shall beblown off as well from
bolt holes.
Note Tak e car e of your eyes when compr essiveair is
applied.
2. C lear away sealing r ing mater ials
When a scraper is used to remove cylinder gasket materials adhered to
cylinder head, device unit, and the contact surface of cylinder gasket,
avoid any damage on the contact surface when scraping, and prevent
cylinder gasket materials from entering tappet holes, cooling-water sleeves,
and bolt holes.
Note Do not damage each sur face when scr aping.
3. C lean the combustion chamber
A steel wire brush will be used to clear all carbon deposits away from the
combustion chamber.
EM.2-6 Cleanup /inspection on each spare part

4. Clean the valve guide

All valve guides may be cleaned using brush and solvent.

5. Clean the cylinder head

The cylinder head maybe cleaned using soft brush and solvent.
Note Do not wash the cylinder head with br ush inside
a hot container , or it will be ser iously damaged.

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6. Check the planeness of cylinder head
(a)Using precise ruler and feeler gage, measure the planeness on the
bottom surface of cylinder head, and check for flexuralde flection on the
contact surface between cylinder head and inlet /outlet manifold.
(b)The planeness on the bottom surface of cylinder head shall be
0.05mm.
(c)The planeness on the contact surface between cylinder head and inlet
/outlet manifold shall be 0.10mm.
(d)The cylinder head shall be changed if the measured planeness is greater
than the foresaid value.

7. Check for cracks on the cylinder head

(a)Using color penetrating fluid, check whether there’s anycrack on
combustion chamber, at air inlet/outlet hole, and atthe surface or on the
top of the cylinder head.
(b)The cylinder head needs to be changed if any crack isfound.

8. Clean the valve

(a)A spacer scraper may be used to clear away all carbondeposits from
the valve.
(b)A steel wire brush may be used to thoroughly clean thevalve.
Note B e car eful enough to avoid any damage on
the sur face of valve seat.
Cleanup /inspection on each spare part EM.2-7

9. Inspection on the abrasion degree of valve rod and

guide.
(a)An amesdial may be used to measure the inner diameter of guide.
Standard inner diameter (8.01-8.03) mm

(b)A micrometer may be used to measure the external diameter of valve

rod.

External diameter of valve rod, and standard clearance(mm)

External diameter of
Standard clearance Max. clearance
standard valve rod
Engine
Air Air Air
model Air inlet Air inlet
exhaust inlet exhaust

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valve valve
valve valve valve

10. The valve guide shall be changed when necessary.

(a)Heat the cylinder head to approx. 90 .

(b)The valve guide may be struck out using SST and hammer.
SST 09201-60011

(c)A caliper gauge may be used to measure the diameter of installation

hole for valve guide on cylinder head.
Diameter of installation hole for standard valve guide
(13.000 13.018) mm
EM.2-8 Cleanup /inspection on each spare part

(d)Selection of new valve guide

If the diameter of installation hole for valve guide on cylinder head is
greater than 13.027mm, the installation hole needs a re-boring to ensure
the diameter is within (13.050 13.077) mm, and the external diameter
for 0.05mm valve guide (an increased size for repair purpose) will be
applicable. the external diameter for standard valve guide shall be within
(13.045 13.060mm .
(e)Using copper rod and hand hammer, the valve guide shall be struck to
a degree that the opening snap ring is able to contact cylinder head.
(f)To make the clearance between valve guide and new valve rod meet
relevant standard &requirement, a 8mm sharp reamer shall be used to
ream the inner diameter of valve guide.
Standard clearance:
Air inlet valve (0.025 0.060)mm
A ir exhaust valve (0.030 0.065)mm

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11. Check and abrade the valve
(a)An abrading method will be applied to clear away any indent
or carbon deposit from the valve.
(b)Check whether the cone angle on valve surface has been
abraded to a correct angle.
Cone angle on valve surface 44.5
Note: The abraded amount shall be decreased to a Min.
degreewhen possible yet sufficient to remove any damage
remainedon the surface.

(c)Inspection on edge thickness for valve

Min. edge thickness specified as below
A ir inlet valve 0.5mm
A ir exhaust valve 0.8mm
T he valve shall be changed whereby edge thickness on the head of valve
is less than Min. value.

edge thickness

(d)Inspection on the whole length of valve

Standard whole length of valve mm
Standard whole length
M in. length
of valve
E ngine
A ir
model A ir inlet A ir exhaust A ir inlet
whole length inlet
valve valve valve
valve

The valve shall be changed whereby the whole length of valve is less than
Min. value.
 Cleanup /inspection on each spare part EM.2-9

(e)Check whether the valve rod has been abraded too much on endsurface.
If it does occur, a grinding machine may be used to repair the end surface,
or the valve shall be changed.
Note Do not mak e an over-abr asion to avoid thewhole
length of valve is less than M in. value.

12. Check and clean the valve seat

(a)A 45 carbide tool will be used to repair or modify the valve seat.
Extra metals need to be cut off when cleaning the valve seat.
(b)The valve may be installed after a thin layer of or white lead
film has been applied to the sealing surface of valve. When the valve seat
is being pressed naturally, make the valve rotating against the valve seat.

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(c)The valve surface and the valve seat shall be checked as per the following:
-If the valve surface shows blue on the 360 circumference, it indicates
that the valve is homocentric, if not, the valve needs to be changed.
-If the valve seat shows blue on the 360 circumference, it indicates that
width the valve guide and the valve seat are homocentric, if not, the valve seat
needs to be abraded and repaired.
-Check whether the contacting width between valve seat and the middle
of valve surface is within (1.2 1.6) mm; If not, a modification to the
valve seat shall be made as per methods stated below:
-If the valve seat is much higher than the valve surface, 30 and 45
carbide tools shall be used to modify the valve seat.

- If the valve seat is much lower than the valvesurface, 60 and 45

carbide tools shall be used to modify the valve seat.
EM.2-10 Cleanup /inspection on each spare part

(d)The valve and the valve seat may be manually abraded using
carborundum.
(e)Following a manual abrasion, the valve and the valve seat shall be
cleaned.

13. Check the valve spring

(a)A steel square will be used to check theperpendicularity of valve
spring.
Max. allowable value 2.0 mm
T he spring needs to be changed if the perpendicularity is greater than
Max. allowable value.

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(b)A vernier caliper will be used to check the freelength of valvespring.
Free length 47 0.5 mm
T he valve springshallbechangedifitcannotsatisfyspecifiedrequirements.

(c)A spring tester will be used to check the tensile force for each spring
having specified installation length.
Installation length:40.6 mm
Standard installation tensile force 345 N
M in. installation tensile for ce 282 N
T he spring shall be changed if the installation tensile force is less than
Min. installation tensile force.

14. Inspection on rocker and rocker-shaft

(a)Inspection on rocker-shaft
Verify by visual check the contact surface betweenrocker-shaft and the
push rod. If the contacting ballsurface or circular arc surface between
rocker-shaftand the push rod has been abraded much or even damaged,
the two contacting surfaces must be repaired, or the rocker-shaft shall be
changed.
 Cleanup /inspection on each spare part EM.2-11

(b)Measure the clearance between rocker and rocker-shaft

Standard value (0.018 0.046)mm
M ax. value 0.08 mm
R ocker and rocker-shaft shall be changed if the clearance is greater than
Max. value.

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(c) Check whether the direction on the rear end of air valve rocker-shaft
is correct. And the valve spring and the rocker-shaft may be assembled as
indicated in the figure. During assembly, special maintenance tools may
be used for an installation of clamps. If the contact surface between valve
and.rocker shaft as been much abraded oil stone provided for valve
refacer may be used for abrading, or they may be changed.

SST 09207-71010
upward

front
convexity

convexity position

15 I nspection on hydr aulic tappet and push r od

(a)Inspection on hydraulic tappet
-A micrometer will be used to measure the external diameter of hydraulic
tappet, then an inner-diameter amesdial will be used to measure the
diameter of installation hole for hydraulic tappet on device unit.
Standar d clear ance value (0.012 0.056)mm
M ax. value 0.100 mm
Hydraulic tappet shall be changed if the actual clearance exceeds Max.
value.
EM.2-12 Assembly of cylinder head

-When hydraulic tappet is submerged in light oil, push the plunger piston
for several times to discharge air insidethe hydraulic tappet.
SST 09276-71010

-During a settlement test aimed at an inspection on the hydraulic tappet,

a sealing settlement tester may be used to apply a 196N force onto the
plunger piston. And measure the time it takes to drop for 1mm after it
has dropped for about 2mm.
-Sealing &settlement time when at 20 if the timeto drop for
1mm can not reach (7 50)seconds, the hydraulic tappet shall be changed.
(b)Inspection on push rod
-Max. radial runout at the middle of push rod shall be checked as
indicated in the figure, and the push rod shall be changed if the actual
runout is greater than 030mm.

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-Check whether the oil hole on push rod has been blocked,if so,
compressive air may be applied to blow off any blocked material.

16. Inspection on inlet /outlet manifold

(a) Precise ruler and feeler gage may be used to check whether the surface
contacting cylinder head has any flexual deformation.
Max. flexure 0.2 mm for inlet manifold; 0.7mm for outlet manifoldThe
manifold shall be changed if the flexure is greater than Max. value.
(b) The planeness on the surface where the inlet &outletmanifold are
connected with cylinder head shall not be greater than 0.4mm. If the
actual planeness is greater than 04mm,inlet &outlet manifold shall be
changed, or the connection surface shall be cut by milling machine to a
smooth degree,with Max milling amount as 0.5mm.

Assembly of cylinder head

1. Check After a washing, the cylinder head, air inlet /outlet duct
and the combustion chamber shall be clean, and without any scratched,
knocked, or damaged trace on fabricated surface; and without any casting
defect on the surface of cylinder head.

Note:
1. The thickness of cylinder head conforming to Class E ur opean
standar d shall be 0.5mm smaller than that confor ming to C lass
E ur opean standar d; A nd there’ s a mar k E 3 made on the r ight
side of cylinder head confor ming to C lass E ur opean standar d,
and the other one does not have this mar k.
2. A ny mis-installation across the E uropean- cylinder head and
the E ur opean- cylinder head is unallowable. I f E ur opean-
cylinder head was installed onto E ur opean-I I device by mistake, it
might make the valve touch the piston I f E ur opean- cylinder
head was installed onto E ur opean- device by mistak e, the
per for mance of engine might be degr aded, and other failur es might
occur accor dingly.
 Assembly of cylinder head EM.2-13

2. Matching air inlet valve with air exhaust valve

After the bottom surface of cylinder head has been put level on work
bench and is facing upward, air inlet &exhaust valves will be installed
onto the cylinder head as per the sequence “exhaust-inlet-inlet-exhaust-
exhaust-inlet-inlet-exhaust”, and could be inserted into the valve guides
IN smoothly after installation without any loose.
Note Pr ior to the matching, check the valve guide r od,
and ensure ther e’ s no any knocked , scratched or damaged
EX tr ace on the coned sealing sur face of valve.
3. L eakage test on sealed parts of valve and its seat hole
T he cylinder head having been installed with air inlet /exhaust valve will
be put to a position for leakage test, and the side of cylinder head having
air inlet /exhaust duct must face upward. When the tail end of valve rod
is being pulled by hand, fill relevant air inlet /exhaust ducts with clean
kerosene and wait for (5~6) seconds, if kerosene from the sealing band of
valve does not flow into the combustion chamber, it indicates that cylinder

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head has no any leakage; In case of leakage, the valve and its seat hole
shall be abraded accordingly.
4. A br ading on valve and valve seat hole
(a)A fter air inlet (exhaust) valve is removed, appropriate amount of
abrasive sands must be applied evenly to the coned sealing surface of air
valve and to the valve seat hole, then be installed into valve guide for an
abrasion by special abrading tool for (7~10) minutes.
(b)A fter air inlet (exhaust) valve is removed, kerosene will be used to
wash residual abrasive sands on valve, in the valve seat hole, inside the
combustion chamber, or inside the air inlet /exhaust duct.
R emark:Valves after an abrasion are not interchangeablewhen washing the
removed valves, they shall be placed in order by sequence to avoid any
mis-installation and misdetermination at a later stage.

marked with green color 5. Pressed installation of air inlet /exhaust valve
upward (a)A ppropriate amount of clean machine oil shall be taken out from
machine oil pot and be applied to the rod of eight air inlet / exhaust
valves respectively, then, have the cylinder head fixed onto a clamping
fixture applicable to the pressed installation of valves.
(b)I nstall eight valve spring seat gaskets successively into place.A nd
the number of gaskets must be correct.
(c)A special press tool shall be used during the pressed installation of
eight valve oil-seals.

Note F or ce applied to the oil-seal could not be too big,if the pr essed oil seal deviates fr om the
installation position, it shall be taken out and discar ded accor dingly,and may not be r e-
used any longer .

(d)Put the valve spring and the valve spring seat into place successively.
R emark
-T he smaller pitch end (viz colored end )of valve spring must be put to the downside.
-Different from air inlet valve, the spring seat on air exhaust valve has a rotatable mechanism, which can not be mis-installed.
SST 09202-43013
(e)Using a special press tool applicable to valve, each locker clamp of valve may be pressed into the cone hole on the cap of air inlet
/exhaust valve.
EM.2-14 Assembly of cylinder head

(f)To have the locker clamp of valve well connected with the spring seat
and the valve rod, a copper hammer may be used to strike gently against
the tail end of each valve rod.
6. Installation of spark plug component
(a)R espective sealing gasket shall be installed onto the spark plug sheath,
and the level end of sealing ring must be connected with the flanged
surface of socket.
(b)Insert the spark plug into the sleeve of spark plug.
(c)Four sets of spark plug and sleeve component shall be manually installed
into (by 3 4 threads) the installation hole on the right side of cylinder
head, and be tightened with a spark plug wrench.
T ightening tor que (20 3)N m

7. Installation of front water-tight cover plate

(a)A layer of varnish shall be applied evenly onto both sides of
spacers used for the front water-tight cover plate of cylinder head,
which will be adhered to the inner surface of front water-tightcover plate.

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A nd make it facing the bolt hole exactly.
( b)T wo M 8 20 bolts with standard spring washer may be
used to fix the front water tight cover plate as well as spacer component
onto the front side of cylinder head.
T ightening tor que (12 2)N m

8. Installation of rear fender onto cylinder head

(a)A layer of varnish shall be applied evenly onto both sides of sealing
spacer for rear fender, which will be adhered to the surface where the rear
fender is linked with cylinder head. And make them facing four installation
holes exactly.
(b) F our M 8 14 bolts with standard spring washer may be
used to fix the rear fender onto the rear end surface of cylinder head.
T ightening tor que ( 12 2)N m
9. I nstallation of cooling liquid temper atur e sensor
(a)A fter an appropriate amount of L e tai branded anaerobicglue 243
has been applied to the threaded part of cooling liquid tempe raturesensor,
manual screw it into the installation hole in front of cylinder head by
3 4 thread.
(b)T ighten it with a wrench.
T ightening tor que ( 20 3)N m

10. I nstallation of connector component onto water outlet

pi p
(a)R ubber plug shall be installed onto the connector.
(b)A layer of varnish shall be applied evenly onto both sides of connector
spacers, which will be adhered to the =surface where the connector is
linked with cylinder head.Make it facing the installation hole exactly.
( c) T wo M 8 25 bolts with flat washer and standard spring
washer may be used to fix the connector at water discharge hole.
T ightening tor que ( 12 2)N m
 Reinstallation /restoration of cylinder head EM.2-15

Reinstallation /restoration of cylinder head

1. Installation of cylinder gasket
Cylinder gasket will be installed onto the device plane, and be fixed
using positioning pin.
2. Installation of cylinder head
The cylinder head component may be installed onto the cylinder gasket
on device unit, be positioned by two positioning pin sleeves, and befixed
using ten M12 cylinder-cover bolts plus three M8 cylinder-cover bolt
with cylinder-cover bolts &washers . Based on the sequence indicated
in the figure, a wrench will be used to screw ten M12 bolts to an extent
as 90N m, followed by a complete unscrewing, then a re-screwing to
90N m The tightening torque for three M8 bolts shall be 20 N.m.
Finally, an 100% verification needs to be performed using a fixed torque
wrench.

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3. Rocker-shaft assembly
upward (a)Two rocker-shafts inside each cylinder may be fixed together via one
special clamping plate.
(b)The rocker-shaft assembly shall be installed onto two studbolts on
front
convexity the cylinder head in such a way that one endofrocker-shaft having dummy
club (its surface facing upward) will be backward.
SST 09207-71010

convexity position (c)Two M8 nut with flat washer may be manually screwed onto
stud bolt; Screw the short threaded end ofthree bolts (fixing the rocker-
shaft ) into the fixed seat for rocker-shaft, followed by a tightening made
push rod progressively in two steps as from the middle to two sides as shown
in the figure .
push rod Tightening torque ( 18 3)N m
(d)A fter a layer of clean machine oil has been applied to the ball surface
on two ends of the push rod, the lower end will be installed into a ball
socket on the tappet cap, while the upper end will be pressed by a special
press rod into the ball socket of rocker-shaft while the crankshaft is
rotating.

4. Installation of valve chamber cover

Cotton cloth may be used to clean sealing band on the plane of cylinder
head, after which valve chamber cover will be installed onto three bolts
used to fix rocker-shaft for cylinder head; when the rubber sealing ring on
the bottom of valve chamber cover is facing exactly to sealing band on
theplane of cylinder head,components like bolt&washer used to fix three
valve chamber covers will be installed onto the fixing bolt of rocker-shaft,
followed by a fixing with three cap nuts, plus a tightening made from the
middletotwoends.
Tightening torque ( 5 1) N m
EM.2-16 Reinstallation /restoration of cylinder head

5. Installation of inlet &outlet manifold

(a)Install air-inlet manifold components onto eight stud boltson the left side
of cylinder head, and have the positioning pinfacing exactly to its installation
hole.
(b)Install the lower part of air inlet /exhaust manifold onto eight stud
bolts on the left side of cylinder head, followed by a fixing using relevant
components like nut, washer, etc. plus a tightening made from the middle
to two sides.
Tightening torque ( 50 5)N m
(c)I nstall dust-cover provided for the lower part of air-inlet manifold
onto the surface where the lower part and the upper part of air-inlet
manifold are connected, so as to prevent any foreign material from entering
air inlet duct prior to the assembly of upper part.
(d)Installation of thermal baffle for wiring harness.
(e)Two M6 18 bolts with flat washer and light-typespring washer
will be used to have
the thermal baffle for wiring harness fixed onto the lowerpart of air-inlet

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manifold.
T ightening tor que ( 7 2) N m
(f)Installation of the upper part of air-inlet manifold
-Following a dismantle of dust-cover from the lower-part of air-inlet manifold,
connection spacers shall be installed onto a plane where the lower part and
the upper part of air-inlet manifold are connected, and shall face to six
installation holes exactly.
-T he upper part of air-inlet manifold shall be installed onto gaskets where the

lower part and the upper part of air-inlet manifold are connected, and have six installation holes facing exactly to relevant spacers, and
to six holes on the low part.
-Six M8 30 hexagonal socket head bolts with flat washer and standard spring washer will be used for fixing purpose, and
shall be tightened as per the sequence “from the middle to two ends”: a pre-tightening may be made using a pneumatic wrench before
a re-tightening to specified torque using a fixed-torque wrench.
Tightening torque ( 16 3)N m
(g)Installation of dead plate and the manifold supporting frame
-Using two M8 16 bolts with flat washer and standard spring washer , dead plate may be installed onto front end surface at
the lower /upper part of inlet manifold to link the lower part with the upper part. T ightening torque (16 3)N m
-One M8 16 bolt with flat washer and standard spring washer will be used to have the upper part of manifold supporting
frame on the rear side of cylinder head fixed onto the upper part of inlet manifold. And two bolts on manifold supporting frame may
be tightened using a fixed-torque wrench.
T ightening tor que ( 16 3)N m

6. Installation of the fuel distributor assembly

(a)A layer of clean machine oil shall be applied evenly to the external edge of
sealing ringwhere four fuel injectors of the fuel distributor assemblywill be
linked with the air inlet manifold.
(b)When four fuel injectors are facing exactly to respective installation hole at
the lower part of air-inlet manifold, and when one side having fuel pressure
adjustor is towards the front side of engine, press and install four fuel injectors
to the lower part of inlet manifold.
(c)The fuel distributor assembly will be fixed using two M8 25 bolts
with flat washer and standard spring washer applied to the lower part
of inlet manifold.
Tightening torque ( 18 3)N m
Reinstallation /restoration of cylinder head EM.2-17

7. Installation of wiring harness on engine

(a)Using fixing clips, the rear end of wiring harness may be fixed to the
rear end surface of cylinder head, and one M8 20 bolt with flat
washer and standard spring washer is usable to fix a manifold
supporting frame. And the tightening shall be performed at a later stage.
(b)At the place adjacent to fuel guide rail, wiring harness needs to be fixed
onto fuel guide rail using two nylon strips,and extra part on the tip of
nylon strip shall be cut off using scissors.
(c)Four plugs provided for four fuel injectors on the wiring harness will
be inserted into relevant sockets provided for four fuel injectors.

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8. Installation of ignition coil components
Using three M 6 35 bolts with flat washer and light type spring
washer , ignition coil may be fixed on relevant supporting frame: flat
washer shall be applied to one side close to the ignition coil, and light-
type spring washer shallbe applied to one side close to the supporting
frame provided for ignition coil, followed by a tightening of M6nuts.
T ightening tor que ( 7 2) N m
9. I nstallation of high-tension damping wir ing
Two ends of high-tension damping wiring shall be connected to ignition
coil and spark plug respectively as indicated by relevant marks made on
high-voltage line and ignition coil.