If the valves have been ground in, they must be installed on their seats, as the wear pattern of the valves varies.
- On a 1.6L engine, clean the semicircular plug and its seat in the cylinder head. Cover the surface of the plug with sealant and insert it into the head.
- Insert the valves into the valve guides. Lubricate the valve stems. When installing the old valves, insert them into their old guides. The same applies to lapped valves.
- Place the oil deflector caps on the valve stems and press them down with a tube. The inlet valve oil deflector caps are painted brown at the top, and the outlet valve caps are black, as shown in Fig. 61.
Fig. 61. Oil deflector caps. The marked surfaces are either brown (1 - intake valves) or black (2 - exhaust valves).
- Install the valve springs on the cylinder head (when reinstalling springs on the old valves). Install the upper spring cups and install the valve tool to compress the springs. If the end of the valve stem protrudes from the upper spring cup, insert both halves of the valve cotter into the groove of the stem and slowly release the valve tool.
- Hit the valve stems from above with a plastic hammer. This will cause the poorly installed valve crackers to pop out. As a precaution, place a rag on the ends of the springs to prevent the parts from flying apart.
- If you need to install spark plug bushings (1.6L engine), press new bushings into the head so that they protrude above the upper surface by 46.6–47.4 mm.
- Insert the pushers and adjusting washers into their original places. Lubricate the parts well.
- Check the surface of the cylinder head and cylinder block and be sure to remove traces of the old seal. After washing the cylinder block, remove any remaining detergent from the threaded parts under the cylinder head bolts.
- Install all parts removed from the cylinder head.