Valve Spring: Service and Repair

VALVE SPRINGS

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

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

8. Position piston of cylinder to be processed to DTC by rotating the crankshaft clockwise. DO NOT crank engine. DO NOT rotate engine backward.

CAUTION: Make sure the crankshaft lock is in position and properly secured for each cylinder being serviced. Failure to do so may result in damage to the vehicle or personal injury.

9. Install crankshaft lock, special tool #8932.
10. Seal injector hole with adaptor # 9534 and retain with original tensioning claw.
11. Connect regulated air supply to special tool # 9534 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 each exhaust valve spring retainer. Use the cam bearing cap threaded holes to position service tool for removal of intake valve spring retainers.





12. Compress valve spring (Fig. 25).
13. Remove valve collates (Fig. 25).





14. Remove top valve spring retainer and valve spring (Fig. 26).





15. Remove valve stem seals (Fig. 27).
16. Remove bottom valve spring retainer (Fig. 26).

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

17. Repeat procedure for each cylinder as necessary.

INSTALLATION - VALVE SPRINGS

NOTE: Inspect all valve springs and retainers for wear or damage. Replace as necessary. Do Not reuse gaskets.

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. Install crankshaft lock, special tool #8932.
3. Seal injector hole with adaptor # 9534 and retain with original tensioning claw.
4. Connect regulated air supply to special tool # 9534 and pressurize the cylinder to 5 bar (73 psi.).
5. Install lower valve spring retainer (Fig. 26).





6. Install valve stem seal (Fig. 28).
7. Install valve spring (Fig. 26).
8. Install valve spring retainer (Fig. 26).

NOTE: Using valve service tools #9307, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at the top of each exhaust valve spring retainer. Use the cam bearing cap threaded holes to position service tool for installation of intake valve spring retainers.

NOTE: Ensure that the valve keepers are seated properly.

9. Compress valve and install valve collates (Fig. 25).

CAUTION: Make sure the crankshaft lock is in position and properly secured for each cylinder being serviced. Failure to do so may result in damage to the vehicle or personal injury.

10. Repeat procedure for each cylinder as necessary.
11. Remove special tooling from cylinder head.
12. Position piston of #1 cylinder to ignition TDC.
13. Install camshafts and check basic position.
14. Install top guide rail.
15. Install front cover at cylinder head.
16. Install timing chain tensioner with new gasket.
17. Install cylinder head cover.

WARNING: (Refer to FUEL SYSTEM WARNING).

18. Install injectors.
19. Reconnect negative battery cable.
20. Start the engine, allow to warm, turn engine off and inspect for leaks. Care must be taken to observe the fuel system warning.
21. Install engine cover.