Cylinder Head Assembly

PROCEDURE
1. Clean all cylinder head components and lay them out on the workbench in the order of assembly.
2. If the valves were lapped, they must be installed in their original seats, since the lapping pattern of each valve is different.
3. Clean the expansion plug and its seat in the cylinder head. Coat the plug surface with sealant and insert it into the head.
4. Insert the valves one at a time into the valve guides. The valve stems must be well lubricated. When reinstalling valves, insert them into their original guides. The same applies to lapped valves.
5. Install the valve stem seals onto the valve stems and press them firmly into place using a piece of tubing.
6. Install the valve springs onto the cylinder head (when reinstalling springs on the same valves). Install the upper spring retainers and fit the valve spring compressor to compress the springs. If the valve stem end protrudes above the upper spring retainer, insert both valve keeper halves into the groove of the stem, and slowly release the valve spring compressor.

7. Tap the upper part of the valve stems with a plastic hammer, as shown in the figure. This will dislodge any incorrectly seated valve keeper halves. Place a rag over the spring ends so that parts do not fly off.
8. Install the lifters and adjusting shims in their original positions. Lubricate the parts.
9. Lubricate the camshaft journals and place the camshaft into the cylinder head. Turn the shaft several times to ensure it seats in the bearing bores.

10. Install the camshaft bearing caps. The bearing caps are marked (in a circle) and must be installed as shown in Figure 6.10, i.e., the upper side of the number must face the front of the engine.
11. Install the bearing cap bolts by hand. Then tighten the bolts in several passes, working from the center outward, to a torque of 18 N·m.
12. Adjust the valve clearances.
13. Install the camshaft seal flange on the front side. Coat the flange surface with sealant.
14. Install the coolant outlet housing with a new gasket. Tighten the six bolts and two nuts to a torque of 47 N·m.
15. Install a new gasket and tighten the fuel lines and intake manifold with six bolts and two nuts, evenly in a crisscross pattern, to a torque of 18 N·m.
16. Check that the cylinder head and cylinder block surfaces are clean, and be sure to remove all traces of old sealant. If the cylinder block has been washed, remove any cleaning agent residue from the threaded holes for the cylinder head bolts. The cylinder head can now be installed.