Reassembling

Senders/Contacts Location:

NOTE: Special Tools Required: 5021, 5025, 5034, 5219, 5222. All senders/contacts are located on the left side of the cylinder head and block.

Valve Stem Height Measurement:

Valve Stem Measurement:

CHECK VALVE STEM HEIGHT POSITION:

NOTE: This measurement should be carried out to ensure that there is sufficient space for valve adjustment.

1. Place gauge 5222 in cylinder head:
2. Slide measuring ring to a position above valve stem.
3. Press valve against valve seat with a finger.
- Valve stem must not touch measuring ring.
- If valve stem touches measuring ring, the valve stem must be shortened.
- Max. grinding: 0.5 mm (0.02 in).
- Min. 3.5 mm (0.138 in) from valve lock and end of valve stem.

Valve Stem Seal Location:

Valve Stem Seal Installation Tool #5219:

Valve Spring Components:

INSTALL VALVE COMPONENTS:
1. Install lower valve spring seat.
2. Install new valve stem seals:
- Seals on intake valves only.

NOTE: Always use the protective sleeve supplied with new parts.

- Oil and place valve in position.
- Place protective sleeve on valve stem.
- Use tool 5219 to fit seal. The tool should abut seal flange.
- Remove protective sleeve.
3. Install valve spring.
4. Install upper spring seat.
5. Install valve locks.
6. Install rubber seal.

Tappet Installation:

Camshaft Installation:

Tool #5021, Press Tool:

INSTALL TAPPETS AND CAMSHAFT:
1. Lubricate and install tappets (valve depressors) and adjusting shims:
- Place in same position as removed.
2. Lubricate:
- bearing shells
- cam lobes
3. Install camshaft and caps:
- Apply sealant, P/N 1161027-6, to the sealing surfaces toward cylinder head of front and rear caps.
- Place camshaft and rear bearing cap (axial bearing) on cylinder head. Place rubber seal in position.

NOTE: Guide pin for timing gear should face UP.

4. Use press tool 5021 to depress camshaft. Use rear bearing cap as guide.
5. Tighten nuts for rear cap only lightly.
6. Lubricate and install another three caps. Tighten nuts only lightly.
7. Remove press tool 5021.
8. Lubricate and install center bearing cap.
9. Torque nuts for bearing caps to 20 Nm (14 ft lbs).

Camshaft Front Seal Installation:

INSTALL FRONT SEAL:
1. Grease oil seal and shaft.
1. Use socket tool 5025 to install seal.
3. Check that rubber edges of seal are not damaged.

Cylinder Head:

INSTALL EXTERNAL CYLINDER HEAD COMPONENTS:
1. Install thermostat, 0-ring and housing.
2. Install lifting eyelet.

ADJUST VALVE CLEARANCE:
- See valve adjustment procedure.