Removal Procedure
Follow Steps to remove the harness assemblies for the electronic unit injectors. Place a temporary identification mark on the connections (1) for the harness assembly (4) for the electronic unit injectors (2).
Use a deep socket to remove the connections (1) from the electronic unit injectors (2). Cut the cable ties (3).
Disconnect the plug (6) from the harness assembly (4).
Use Tooling to remove the circlip (5).
From the outside of the valve mechanism cover base (7), push the harness assembly (4) inward. Withdraw the harness assembly from the valve mechanism cover base. Remove the O-ring seal (8) from the harness assembly (4). Discard the O-ring seal. Repeat Steps in order to remove the remaining harness assemblies.
Follow Steps to position the appropriate piston at top dead center.
Install Tooling in position on the cylinder head in order to compress a valve spring (10) for the appropriate piston.
Use Tooling in order to compress the valve spring (10) and open the valve slightly. Do not compress the spring so that the valve spring retainer (9) touches the valve stem seal.
Use Tooling in order to rotate the crankshaft carefully, until the piston touches the valve. Not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.
Continue to rotate the crankshaft and gradually release the pressure on Tooling until the piston is at the top dead center position. The valve is now held in a position that allows the valve spring to be safely removed.
Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 6, 2 with 5, and 3 with 4. Ensure that all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders.
Apply sufficient pressure to Tooling in order to allow removal of the valve keepers (8).
Do not compress the spring so that the valve spring retainer (9) touches the valve stem seal. Remove the valve keepers (8). Slowly release the pressure on Tooling. Remove the valve spring retainer (9) and remove the valve spring (10). If necessary, remove the valve stem seals.
Repeat Steps to remove the remaining valve springs from the appropriate cylinder.
Installation Procedure
Inspect the valve springs (10) for damage and for the correct length.
If necessary, install a new valve stem seal onto the valve guide. The outer face of the valve guide must be clean and dry before installing the valve stem seal. Install the valve spring (10) onto the cylinder head. Position the valve spring retainer (9) on the valve spring (10).
Install Tooling in the appropriate position on the cylinder head in order to compress the valve spring (10).
Apply sufficient pressure to Tooling in order to install the valve keepers (8). Do not compress the spring so that the valve spring retainer (9) touches the valve stem seal. Install the valve spring keepers.
Carefully release the pressure on the Tooling.
Repeat steps for the remaining valves.
The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves.
Remove the Tooling.
Use Tooling to rotate the crankshaft through approximately 45 degrees. This will ensure that the appropriate valve is clear of the piston. Lightly strike the top of the valve with a soft hammer in order to ensure that the valve keepers (10) are properly installed. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following cylinders. 1 and 6, 2 and 5, and 3 and 4. Remember that the crankshaft must not be turned while the valve springs are removed. Ensure that all of the valve springs are installed before changing from one pair of cylinders to the other pair of cylinders. If all valve springs do not require replacement, the springs must be replaced in pairs.
Follow Steps to install the harness assemblies for the electronic unit injectors.
Ensure that the harness assembly (4) for the electronic unit injectors and the bore in the valve mechanism cover base (7) are clean and free from damage. Replace any damaged components.
Use Tooling to lubricate a new O-ring seal. Install the new O-ring seal (8) onto the harness assembly (4) for the electronic unit injectors.
From the inside of the valve mechanism cover base (7), push the harness assembly (4) into the valve mechanism cover base.
Use Tooling to install the circlip (5). Connect the plug (6) to the harness assembly (4) for the electronic unit injectors.
Use a deep socket to install the connections (1) to the electronic unit injectors (2). Use Tooling to tighten the connections to a torque of 2.5 N�m (22 lb in). Install a new cable tie (3). Ensure that cable ties to OE specification are used. Repeat Steps for the remaining harness assemblies.
Install the rocker shaft assembly.
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