Insert the appropriate valve into its guide (if new valves are installed, insert each one in the specific position it was ground into), making sure. that the valve stem is well lubricated with clean engine oil. If these are old parts, they must be put in their original position.
Install the valve seat.
It is essential that new valve stem seals be shipped with a bushing that sits over the key groove in the valve stem to prevent damage to the seal. If no bushing is available, wrap a short piece of tape around the top of the valve stem to cover the cracker groove.
Lubricate the valve stem seal with clean engine oil, then draw the seal down the valve stem using a suitable tube or ring until the seal is fully seated on the spring seat. Remove the installed bushing or band from the valve stem.
Install the valve spring and spring cap.
Install the spring compressor, compress the valve spring until the spring cup passes over the cotter groove in the valve stem.
Apply some grease to the cotter groove, then install the cotters into the groove with the narrow ends closer to the spring. The grease should keep them in the groove.
Slowly decompress the spring compressor, making sure that the cotters do not move in the groove. When the mechanism is fully unclenched, lightly tap the top of the valve assembly with a soft-shell hammer to seat the parts completely.
Do the same for the rest of the valves (checking, if old parts are used, that they are in their original position).
On engines with two camshafts, install the hydraulic valve lifters in the cylinder head to their original position. Lubricate the holes heavily with oil, and if new valve lifters are being installed, then first immerse them in a container of clean engine oil and squeeze each (hand) several times to complete them.
Install the following components where required:
- A) On engines with two camshafts, install the camshafts.
- V) Install the thermostat housing (together with a thermostat on 1.4 and 1.6 liter engines), using a new oil seal where required (chapter 3).
- c) Install spark plugs (chapter 5).
- d) Install manifolds (chapter 4).
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