Fig. 2.124. Installing the valve in the cylinder head
Insert the valve into the cylinder head (fig. 2.124).
Place the tip of the tool (Mot. 1511) on the valve stem (the inner diameter of the tip must be equal to the diameter of the rod).
Fig. 2.125. Holding the valve in the seat
Keep the valve pressed against the seat (fig. 2.125).
Install the oil seal (not oiled) on the tip.
Fig. 2.126. Installing the oil deflector cap
Slide the oil seal until it passes over the tip (fig. 2.126).
Fig. 2.127. Removing the tip of the device
Remove the tip (fig. 2.127).
Fig. 2.128. Installing the mandrel on the oil deflector cap
Install the mandrel onto the oil seal (fig. 2.128).
Note: The inside diameter of the mandrel should match the diameter of the valve stem. In addition, the bottom of the mandrel should partially rest against the valve stem seal, which serves as a support washer for the valve spring.
Fig. 2.129. Pressing on the oil deflector cap
Press the valve stem seal into place by tapping the top of the mandrel with your palm until the valve stem seal contacts the cylinder head (fig. 2.129).
Repeat the above operations for all valves.
Fig. 2.130. Installing the valve spring
Install the springs and spring plates (fig. 2.130).
Fig. 2.131. Installing crackers
Insert the crackers using curved tongs (fig. 2.131).
Install the thermostat assembly with a new gasket onto the cylinder head.
Fig. 2.132. The order of tightening the thermostat housing mounting bolts
Tighten the thermostat unit mounting bolts on the cylinder head in the order shown in Figure 2.132 to the required torque (10 Nm).
Install the exhaust manifold with a new gasket.
Fig. 2.133. Tightening order of exhaust manifold mounting stud nuts
Tighten the exhaust manifold mounting stud nuts in the order shown in Figure 2.133 to the required torque (23 Nm).
Install the exhaust manifold heat shield.
tighten the exhaust manifold heat shield mounting bolts to the specified torque (1 Nm).
Caution: Make sure the exhaust manifold heat shield is securely fastened between the oxygen sensor and the manifold (to avoid overheating, which could result in damage to the upstream oxygen sensor wiring).
Tighten the oxygen sensor to the specified torque (4.5 Nm) using tool (Mot. 1495).
Install the inner timing case spacer.
Install the injector housing linings with a new gasket.
Install the oxygen sensor.
Fig. 2.134. Aligning the injector housing gasket
Align the injector housing lining with the cylinder head (from the timing drive side) (fig. 2.134).
Align the mating planes of the injector housing linings with the cylinder head.
Fig. 2.135. The order of tightening the bolts for fastening the injector housing lining
Tighten the injector housing lining mounting bolts in the specified order to the specified torque (21 N·m) (fig. 2.135).