Service Procedure

Note:
If Plugs are removed without cool down, gasoline traces are not an indicator of any engine malfunction

1. Note settings of all electrical devices and then disconnect negative battery cable.

2. Remove right bank spark plug wires.

3. Remove vent tube (fresh air) from right valve cover.

4. Remove plastic heater hose bracket from rear of generator.

5. Remove dipstick bracket bolt from cylinder head.

6. Disconnect wiring bracket at the generator bracket and reposition wires to gain access to valve cover.

7. Disconnect air intake duct at throttle body.

8. Set front wheels in the straight-ahead position and the steering wheel in the "locked", position. Remove shield on lower intermediate shaft. Remove bolt from rag joint to steering gear input shaft. Move shaft to the left of vehicle to gain access to # 3 spark plug.

9. Remove throttle cable support bracket.

10. Remove ignition coil assembly.

11. Remove evaporative valve from intake manifold.

12. Remove right valve cover and store in a safe place, gasket is to be reused and not replaced on any stock units repaired prior to delivery to customers. Any vehicles repaired after customer usage should have both rocker cover gaskets replaced with gasket P/N 10201397.

13. Disconnect PCV valve and tube.

14. Remove left bank spark plug wires and reposition heater hoses to access left valve cover.

15. Remove upper radiator hose support bracket.

16. Disconnect vacuum hose to brake booster.

17. Disconnect temperature gauge sensor wire connector.

18. Remove left valve cover and store in a safe place, gasket is to be reused and not replaced on any stock units repaired prior to delivery to customers. Any vehicles repaired after customer usage should have both rocker cover gaskets replaced with gasket P/N 10201397.

VALVE SEAL REPLACEMENT FOR EXHAUST AND INTAKE VALVES

CAUTION:
On vehicles with very low mileage which have marshaled and not run for an extended period of time, spark plugs may appear to be soot covered. This is considered a normal condition thus not requiring the spark plugs to be replaced.

19. Remove spark plug (through wheel opening where necessary) and install air hose to spark plug adapter J 23590 and attach to cylinder head. Apply air pressure to cylinder.

20. Remove rocker nut and rocker arm.

21. Install tool J 5982-C and rocker arm nut and compress spring. For cylinders 5 and 6 use J 38606 to compress valve springs.

22. Remove valve keepers (2) using a magnet.

23. Carefully release spring tension and remove nut and tool J 5892-C

24. Remove valve spring cap, spring and valve seal.

25. Discard used seal.

26. Insure valve spring seat area is free of any foreign material.

27. Lightly oil new valve stem seal with clean engine oil.

28. Place new valve stem seal onto the valve stem and gently push the seal down to the point where it makes contact with the valve guide.

CAUTION:
Seal alignment is critical and seal may be damaged if incorrectly installed.

29. Place the tool J 42073 over the valve stem and seal, and push the tool down onto the valve stem. Using a small rubber mallet, lightly tap the tool to position the seal on the valve guide until the tool bottoms out against the cylinder head.

30. Remove the installation tool and examine the valve seal. There should be approximately a 1 to 2 mm gap between the bottom of the seal and valve guide.

31. Seal installation is complete.

32. Install valve spring, valve spring cap.

33. Install nut and tool J 5892-C.

34. Compress spring and install valve keepers. Insure keepers are seated properly.

35. Carefully release spring tension and remove tool J 5892-C.

36. Install valve rocker arm and nut. Torque nut to 25 Nm (20 lb. Ft.).

37. Remove air hose and spark plug adapter J 23590.

38. Install spark plug.

39. Perform steps 19 through 38 for the remaining exhaust and intake valves on the remaining cylinders.

40. Install the left valve cover and bolts. Torque cover bolts to 12 Nm (106 lb. In.).

41. Connect temperature gauge sensor wire connector.

42. Connect vacuum hose to brake booster.

43. Install upper radiator hose support bracket.

44. Reposition the left bank spark plug wires and install spark plug boots to plugs.

45. Install PCV valve and tube. Reposition heater hoses.

46. Install right valve cover and bolts. Torque cover bolts to 12 Nm (106 lb. In.)

47. Install evaporative valve to intake manifold.

48. Install ignition coil assembly.

49. Install throttle cable support bracket.

50. Reconnect air intake duct to throttle body.

51. Reconnect wiring bracket at the generator bracket and put wires in position over right valve cover.

52. Install dipstick bracket bolt to cylinder head.

53. Install plastic heater hose bracket to rear of generator.

54. Connect vent tube to right valve cover.

55. Place lower intermediate steering shaft in correct position and install bolt to lower rag joint to steering gear input shaft. Torque bolt to 35 Nm (25 lb. ft.). Install shield onto lower intermediate shaft.

56. Install right bank spark plug wires and install spark plug boots to plugs.

57. Install negative battery cable.

58. Start and run engine to verify correct engine operation.

59. Reset all electrical devices as noted in step 1.

60. Install Campaign Identification Label.