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. Install heater union as follows:

NOTE: When using a new cylinder head, a new heater union must be installed.






(a) Apply adhesive part No.08833-00070, THREE BOND 1324 or equivalent, 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 48 mm (1.89 inch) protruding from the cylinder head.

NOTE: Do not tap it in too far.

2. Install EGR cooler, tighten to 8.8 Nm (90 kg.cm, 78 in.lb).
3. Install valves and springs 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: When reusing components, install in their original location.






NOTE: Confirm the correct direction of the valve spring.






(c) Using valve spring compressor Special Service Tool (SST) No. 09202-70020, or equivalent, compress the valve spring and place the 2 keepers around the valve stem.






(d) Using a plastic-faced hammer, lightly tap the valve stem tip to assure proper fit.
4. Install valve lifters and shims, ensure that the valve lifter rotates smoothly by hand.

NOTE: When reusing components, install in their original location.

5. Install Engine Coolant Temperature (ECT) sensor and temperature gauge sender, tighten to:
ECT sensor: 25 Nm (250 kg.cm, 18 ft.lb).
Temperature gauge sender: 15 Nm (150 kg.cm, 11 ft.lb).
6. Install ground strap and throttle cable bracket.
7. Install engine hangers, tighten to: 39 Nm (400 kg.cm, 29 ft.lb).