Head Re-Assembly

Process

1. Refit Valves into seats:This is done using the valve spring compressor when valves are put back in place reinsert springs. Then caps with spring compressed by compressor. refit valve stem seals and shims by holding them in place with grease. release tension slowly. The spring should then return into place and be held in by shims
2. refit valve caps make sure sliding surface of each is lubricated with clean oil.
3. Oil cam shaft bearing surfaces and set cams (Intake and exhaust) in place. With surfaces oiled place bearing caps back onto each bearing and torque to specification make sure the correct cap is on the correct bearing and correct cam. This can be identified on surface of cap, Will be numbered 1 to 5 with correct cam shaft letter either I or E, also direction it should be facing. This is identified by arrow pointing to front of engine. 
4. Bolt head back in place. Insure that bolts are tightened to correct torque of 78Nm (for these engines half was used 38Nm) Tighten each bolt in steps have to be tightened from center out in a clockwise motion. 



Order of bolt tightening on head






Head Bolted in place

5. Re-attach cam gears, Idler gears and belt to front of engine. Make sure each cam gear is on correct cam. Identified by labelling on gear. Attach Idlers, spring and belt. Spring is put in place first. Then the belt needs to be put in place and aligned correctly by tensioning it using cam gears starting from the exhaust side. Belt is put around exhaust cam gear and on inside of idler, then around driving gear that comes off crankshaft, then inside of the intake cam idler, then finally around Intake cam gear.
6. Bolt cam cover in place. Then bolt on last two pulleys then engine will be fully assembled.

       

Fully assembled B5. Shows path of cam belt and correct alignment of gears