Assembly

NOTE:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
^ Replace all gaskets and oil seals with new ones.

1. When using a new cylinder head, install heater union as follows:






(a) Apply THREE BOND 1324, or equivalent, adhesive to the end of the heater union as shown in the illustration.






(b) Using a wooden block and hammer, tap in a new heater union, leaving standard position protruding from the cylinder head.
- Standard protrusion: 48 mm (1.89 inch).

NOTE: Do not tap it in too far.

2. Install valves and components as follows:






(a) Install a new oil seal on the valve guide bushing.
(b) Install these parts:
- Valve (1).
- Spring seat (2).
- Valve spring (3).
- Spring retainer (4).






NOTE: Confirm the correct direction of the valve spring as shown in the illustration.






(c) Using valve spring compressor Special Service Tool (SST) 09202-70020, or equivalent, compress the valve spring and place the two keepers around the valve stem.






(d) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

3. Install the valve lifter and shim, check that the valve lifter rotates smoothly by hand.

4. Install a new gasket and the EGR cooler with the eight bolts, tighten to 8.8 Nm (90 kg. cm., 78 inch lbs.).

5. Install Engine coolant Temperature (ECT) sensor and gauge sender, then tighten as follows:
- ECT sensor: 25 Nm (250 kg. cm., 18 ft. lbs.).
- ECT sender gauge: 15 Nm (150 kg. cm., 11 ft. lbs.).

6. Install ground strap and throttle cable bracket.

7. Install engine hangers, then tighten to: 39 Nm (400 kg. cm., 29 ft. lbs.).