Valve Spring: Service and Repair

REMOVAL - VALVE SPRINGS
1. Disconnect negative battery cable.
2. Remove glow plugs.
3. Remove injectors.
4. Remove cylinder head cover.
5. Remove timing chain tensioner.
6. Remove front cover at cylinder head.
7. Remove top guide rail.
8. Remove camshafts.

NOTE: The timing chain must be held in up position so as not to jam during procedure.

9. Position piston of cylinder to be processed to DTC by rotating the crankshaft clockwise. DO NOT crank engine. DO NOT rotate engine backward.
10. Install crankshaft lock, special tool #8932.
11. Seal injector hole with connection piece and retain with original tensioning claw.
12. Connect cylinder leak tester with adapters and pressurize the cylinder to 5 bar (73 psi.).

WARNING: Valve springs and retainers must be kept in order of the cylinder they were removed.

NOTE: Using valve service tools #9307, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at top of valve spring retainer.





13. Compress valve spring (Fig. 22).
14. Remove valve collets (Fig. 22).





15. Remove top valve spring retainer and valve spring (Fig. 23).





16. Remove valve stem seals (Fig. 24).
17. Remove bottom valve spring retainer (Fig. 23).

NOTE: Inspect all cylinder head components for wear or damage.

18. Repeat procedure for each cylinder as necessary.

INSTALLATION - VALVE SPRINGS

NOTE: Inspect all valve springs and retainers for wear or damage. Replace as necessary.

1. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank engine or rotate engine counter clockwise.
2. Connect cylinder leak tester with adapters and pressurize the cylinder to 5 bar (73 psi).
3. Install lower valve spring retainer (Fig. 23).





4. Install valve stem seal (Fig. 25).
5. Install valve spring (Fig. 23).
6. Install valve spring retainer (Fig. 23).

NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at the top of each valve spring retainer.

NOTE: Ensure that the valve keepers are seated properly.

7. Compress valve and install valve collets (Fig. 22).
8. Repeat procedure for each cylinder as necessary.
9. Remove special tooling from cylinder head.
10. Position piston of #1 cylinder to ignition TDC.
11. Install camshafts and check basic position.
12. Install top guide rail.
13. Install front cover at cylinder head.
14. Install timing chain tensioner with new gasket
15. Install cylinder head cover.
16. Install glow plugs.

WARNING: SERVICE VEHICLES IN A WELL VENTILATED AREA AND AVOID IGNITION SOURCES. RISK OF INJURY TO SKIN AND EYES FROM FUEL JET FLOWING OUT.

17. Install injectors.
18. Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

19. Start the engine and inspect for leaks. Care must be taken to observe the fuel system warning.
20. Install engine cover.