In Vehicle Service
REMOVAL - VALVE SPRINGS AND SEALS1. Disconnect the battery negative cables.
2. Remove the cylinder head cover.
3. Disconnect rocker housing injector harness connector. Remove all injector harness solenoid nuts.
4. Remove injector(s) for cylinder(s) to be serviced.
5. Remove the rocker housing.
6. Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position.
7. Using the crankshaft barring tool # 7471-B (Fig. 33), rotate the engine to position the damper mark in the 12 o'clock position. At this engine position, cylinders # 1 and # 6 can be serviced.
8. Remove the accessory drive belt.
9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover.
10. Divide the crankshaft damper into three equally sized segments as follows:
a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by three (3).
b. Measure that distance in a counter-clockwise direction from the first balancer mark and place another mark on the balances.
c. From the second damper mark, again measure in a counter-clockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock position.
d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair.
11. Compress the valve springs at cyls. # 1 and # 6 as follows:
a. Remove bolts and injector hold-down clamp.
b. Using miller special tool # 9010, remove injector.
c. Install the valve spring compressor mounting base as shown in (Fig. 34).
d. Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clock-wise) (Fig. 35) to compress the valve springs and remove the collets.
e. Rotate the compressor nut counter-clockwise to relieve tension on springs. Remove spring compressor.
f. Remove and replace retainers, springs, and seals as necessary.
g. Do not rotate the engine until the springs and retainers are re-installed.
h. Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets.
i. Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer.
12. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders # 2 and # 5 can be serviced.
13. Repeat the valve spring compressing procedure previously performed and service the retainers, springs, and seals as necessary.
14. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders # 3 and # 4 can be serviced.
15. Repeat the spring compressing procedure previously performed and service the retainers, springs, and seals as necessary.
INSTALLATION
1. Install rocker housing.
2. Install fuel injectors and high pressure fuel lines.
3. Lubricate the valve tips and install the crossheads in their original locations.
4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque.
5. Verify valve lash adjustment.
6. Install cylinder head cover and reusable gasket.
7. Connect battery negative cables.