Installing the valve in the cylinder head
Installing the lower spring seat
1. Lubricate the valve stems with clean engine oil and insert them into place. Install the valves in the places where they were lapped.
2. Install the spring seat. Dip the slinger cap in fresh engine oil and install it over the valve stem, being careful not to damage its sealing lips. To protect the working edges of the oil cap, you can wrap the end of the valve stem with adhesive tape before installation.
3. Install the valve spring and spring cup.
4. Using a special tool, compress the valve spring and install the crackers in the recesses of the valve stem and lubricate them. Remove the spring compressor tool. Repeat this operation for the rest of the valves.
5. Tap the end of the valve stem with a hammer through a wooden block so that all valve elements are clearly installed in their places.
6. Install the thermostat housing to the cylinder head.
7. Screw in the spark plugs.
8. Install the camshaft and valve train with hydraulic tappets.
9. Install the intake and exhaust manifolds.
10. Install the cylinder head (see subsection 3.13.3).
SOHC 6-cylinder petrol engines
Oil seal lubrication
Installing a plastic sleeve on the valve stem to protect the working edges of the oil seal
1. Lubricate the valve stems with clean engine oil and insert them into place. Install the valves in the places where they were lapped.
2. Install the spring seat. Dip the slinger cap in fresh engine oil and install it over the valve stem, being careful not to damage its sealing lips. To protect the working edges of the oil cap, you can wrap the end of the valve stem with adhesive tape before installation.
3. Install the valve spring and spring cup.
4. Using a special tool, compress the valve spring and install the crackers in the recesses of the valve stem and lubricate them. Remove the spring compressor tool. Repeat this operation for the rest of the valves.
5. Tap the end of the valve stem with a hammer through a wooden block so that all valve elements are clearly installed in their places.
6. Install the thermostat housing to the cylinder head.
7. Screw in the spark plugs.
8. Install the camshaft and valve train with hydraulic tappets.
9. Install the intake and exhaust manifolds.
10. Install the cylinder head (see corresponding description in subsection 4.12).
6-cylinder DOHC gasoline engines
Using a tubular mandrel to install an oil seal
Installing the internal valve spring
1. Lubricate the valve stems with clean engine oil and insert them into place. Install the valves in the places where they were lapped.
2. Install the spring seat. Dip the slinger cap in fresh engine oil and install it over the valve stem, being careful not to damage its sealing lips. To protect the working edges of the oil cap, you can wrap the end of the valve stem with adhesive tape before installation.
3. Install the valve spring and spring cup. Early models had two springs per valve. On later models with a single conical spring, the larger diameter of the spring should be located on the side of the cylinder head.
4. Using a special tool, compress the valve spring and install the crackers in the recesses of the valve stem and lubricate them. Remove the spring compressor tool. Repeat this operation for the rest of the valves.
5. Tap the end of the valve stem with a hammer through a wooden block so that all valve elements are clearly installed in their places.
6. Install the thermostat housing to the cylinder head.
7. Screw in the spark plugs.
8. Install the camshaft and valve train with hydraulic tappets.
9. Install the intake and exhaust manifolds.
10. Install the cylinder head (see corresponding description in subsection 5.15).
Diesel engines
External valve spring installation
Installing the upper spring seat
Installing crackers on the valve stem
1. Lubricate the valve stems with clean engine oil and insert them into place. Install the valves in the places where they were lapped.
2. Install the spring seat. Dip the slinger cap in fresh engine oil and install it over the valve stem, being careful not to damage its sealing lips. To protect the working edges of the oil cap, you can wrap the end of the valve stem with adhesive tape before installation.
3. Install the valve spring and spring cup.
4. Using a special tool, compress the valve spring and install the crackers in the recesses of the valve stem and lubricate them. Remove the spring compressor tool. Repeat this operation for the rest of the valves.
5. Tap the end of the valve stem with a hammer through a wooden block so that all valve elements are clearly installed in their places.
6. Install the thermostat housing to the cylinder head.
7. Screw in the glow plugs.
8. Install the camshaft and valve train with hydraulic tappets.
9. Install the intake and exhaust manifolds.
10. Install the cylinder head (see corresponding description in subsection 6.12).