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Valve Stem Oil Seal and Valve Spring Replacement

Valve Stem Oil Seal and Valve Spring Replacement



Special Tools

• EN-840 Valve Stem Oil Seal Remover

• EN-6086 Spring and Wedge Replacer

• EN-6152 Valve Stem Oil Seal Installer

• EN-6171 Valve Spring Key Solvent


For equivalent regional tools, refer to Special Tools (LDK, LHU) .

Removal Procedure

Note

Clean working is condition.



1. Remove all spark plugs. Refer to Spark Plug Replacement .

2. Drain the cooling system. Refer to Cooling System Draining and Filling (LDK/A20NHT) and Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LAU/A28NER) .

3. Remove both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

4. Remove the intake and the exhaust camshaft. Refer to Intake Camshaft and Valve Lifter Replacement and Exhaust Camshaft and Valve Lifter Replacement .

5. Tighten one of the support head (1) in the center of the rail (2) with the fastener (3).


6. Install the EN-6086-5 mounting shaft (1) to one of the EN-6086-6 supports (2).


7. Install the EN-6086-8 knuckle (1) to the EN-6086-5 mounting shaft (2) and install the second support (3) to the mounting shaft (2).


8. Install the lever arm bracket (1) to the cylinder head (2).


• The fixed side of the lever arm bracket install on the left side of the cylinder head but do not tighten yet.

• The not fixed side of the lever arm bracket install on the right side of the cylinder head but do not tighten yet.

9. Fix the EN-6086-5 mounting shaft (1) with both support head fasteners (2).


10. Align the lever arm bracket (1) in the center of the cylinder head on the basis of the spark plug drillings (2).


11. Tighten both EN-6086-6 supports to the cylinder head.

12. Fix the second support head (1) to the rail (2).

Release the heated oxygen sensor 1 electrical connector from the cylinder head.


13.
Note

All wheels must be in contact with the ground.


Fix the crankshaft.

Use a suitable tool.

14. Install the EN-6086-15 compressed air adapter (1) to the spark plug drill (2) of the first cylinder.


15. Subject the first cylinder with compression air.

16. Install the EN-6086-12 adapter part small (1) to the EN-6086-11 removal part small (2).


17. Install the EN-6086-12 adapter part small and the EN-6086-11 removal part small to position 3 to the EN-6086-7 lever arm . Fasten the tools with EN-6086-2 pin .


18. lnstall the EN-6086-7 lever arm to the EN-6086-8 knuckle .

• Use the position 1 of the lever arm.

• Fasten the tools with EN-6086-2 pin .

19.
Note

Note the installation construction units position of the valve stem keys, valve spring retainer and valve spring.


Set the EN-6086-11 removal part small (1) on the intake valve spring retainer (2) on the left side of the first cylinder.


20. To remove the valve stem key (1), valve spring retainer (2) and valve spring (3) press the lever arm downward.


21.
Note

Do not use magnetic tools.


If the valve stem key are out fallen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper .

22. Set the EN-6086-11 removal part small on that intake valve spring retainer on the right side to the first cylinder.

23. To remove from the valve stem keys, valve spring retainer and valve spring press the lever arm downward.

24.
Note

Do not use magnetic tools.


If the valve stem key has become loose, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper .

25. Remove both valve stem oil seal rings with EN-840 valve stem oil seal remover (1) from the cylinder head.


26. Install the EN-6086-12 adapter part small and the EN-6086-11 removal part small to position 1 to the EN-6086-7 lever arm . Fasten the tools with EN-6086-2 pin .


27. lnstall the EN-6086-7 lever arm to the EN-6086-8 knuckle .

• Use the position 3 to the lever arm.

• Fasten the tools with EN-6086-2 pin .

28.
Note

Note the position of the valve stem keys, valve spring retainer and valve spring.


Set the EN-6086-11 removal part small on that exhaust valve spring retainer on the left side at the first cylinder.

29. To remove the valve stem key, valve spring retainer and valve spring press the lever arm upward.

30.
Note

Do not use magnetic tools.


If the valve stem key are loosen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper .

31. Set the EN-6086-11 removal part small on that exhaust valve spring retainer on the right side to the first cylinder.

32. To remove the valve stem keys, valve spring retainer and valve spring press the lever arm upward.

33.
Note

Do not use magnetic tools.


If the valve stem key are loosen, remove the valve stem keys with EN-6086-13 round awl and EN-6086-14 special calliper .

34. Remove the both valve stem oil seal rings with EN-840 valve stem oil seal remover from the cylinder head.


Installation Procedure


1.
Note

Do not press the valve downward.


Install with EN-6152 valve stem oil seal installer (1) the new valve stem oil seal rings to the cylinder head.


• Press the valve stem oil seal ring with the finger downward.

• The EN-6152 valve stem oil seal installer must rest upon at the lower edge of the valve stem oil seal ring.

• Knock with a rubber hammer on the EN-6152 valve stem oil seal installer to sit the valve stem oil seal ring to the cylinder head.

2. Install EN-6086-100-15 pressure adapter 6j (3) to EN-6086-100-10 mounting part (4).


• Remove the fastener (1) from the mounting part (4).

• Remove the spring (2) from the mounting part (4).

• Install the pressure adapter 6j (3) into the mounting part (4).

• Install the spring (2) into the mounting part (4).

• Install the fastener (1) to the mounting part (4).

3.
Note

Only one attempt. If the attempt failed, repeat step 3 to 8 for the exhaust left side and step 9 to 13 for the exhaust right side.


Install the valve stem keys (1) to the EN-6086-100-10 mounting part (2).


• Pull the ring back that the the springs are loosen.

• Install the valve stem keys with the narrow side upward.

• Pull the ring forward till the springs are the valve stem keys locking.

4. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part .

5. Install both parts to the EN-6086-7 lever arm .

6. Install the left exhaust valve spring and the left exhaust valve retainer to the cylinder head.

7. Set the EN-6086-100-15 pressure adapter to the left exhaust valve.

8. Press the lever arm up to audibly engage the left valve stem keys.

9. Install the valve stem keys to the EN-6086-100-10 mounting part .

• Pull the ring back that the the springs are loosen.

• Install the valve stem keys with the narrow side upward.

• Pull the ring forward till the springs are the valve stem keys locking.

10. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part .

11. Install both parts to the EN-6086-7 lever arm .

12. Install the right exhaust valve spring and the right exhaust valve retainer to the cylinder head.

13. Set the EN-6086-100-15 pressure adapter to the right exhaust valve.

14. Press the lever arm up to audibly engage the right valve stem keys.

15. Remove the EN-6086-7 lever arm from the EN-6086-8 knuckle .

16. lnstall the EN-6086-7 lever arm (1) to the EN-6086-8 knuckle (2).


• Use the position 1 from the lever arm.

• Fasten the tools with EN-6086-2 pin .

17.
Note

Do not press the valve downward.


Install with EN-6152 valve stem oil seal installer (1) the new valve stem oil seal rings to the cylinder head.

• Press the valve stem oil seal ring with the finger downward.

• The EN-6152 valve stem oil seal installer must rest upon at the lower edge of the valve stem oil seal ring.

• Knock with a rubber hammer on the EN-6152 valve stem oil seal installer to sit the valve stem oil seal ring to the cylinder head.

18.
Note

Only one attempt. If the attempt failed, repeat step 18 to 23 for the intake left side and step 24 to 29 for the intake right side.


Install the valve stem keys to the EN-6086-100-10 mounting part .

• Pull the ring back that the the springs are loosen.

• Install the valve stem keys with the narrow side upward.

• Pull the ring forward till the springs are the valve stem keys locking.

19. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part .

20. Install both parts to the EN-6086-7 lever arm .

21. Install the left intake valve spring and the left intake valve retainer to the cylinder head.

22. Set the EN-6086-100-15 pressure adapter to the left intake valve.

23. Press the lever arm down to audibly engage the left valve stem keys.

24. Install the valve stem keys (1) to the EN-6086-100-10 mounting part (2).

• Pull the ring back that the the springs are loosen.

• Install the valve stem keys with the narrow side upward.

• Pull the ring forward till the springs are the valve stem keys locking.

25. Install the EN-6086-100-10 mounting part to the EN-6086-12 adapter part .

26. Install both parts to the EN-6086-7 lever arm .

27. Install the right intake valve spring and the right intake valve retainer to the cylinder head.

28. Set the EN-6086-100-15 pressure adapter to the right intake valve.

29. Press the lever arm down to audibly engage the right valve stem keys.

30. Remove the EN-6086-7 lever arm from the EN-6086-8 knuckle .

31. To replace the valve stem oil seals of the cylinders 2 and 3 turn the crankshaft by 180 degrees .


• Set 2 marks (1), by 180 degrees transferred, at the oil pump housing.

• Set 1 mark (2) at the crankshaft balancer.

• A second mechanic must hold the primary timing chain upward.

• Turn clock wise the timing chain 180 degrees .

32. To remove the valve stem oil seals repeat the steps from removal 15 to 35.

33. To install the valve stem oil seals repeat the steps from installation 1 to 31.

34. Turn back the crankshaft 180 degrees against clockwise direction after the exchange of the valve stem sealings of the cylinder 2 and 3.

A second mechanic must hold the primary timing chain upward.

35. Remove the lever arm bracket.

36. Install the intake and exhaust camshaft and valve lifter. Refer to Intake Camshaft and Valve Lifter Replacement and Exhaust Camshaft and Valve Lifter Replacement .

37. Check the timing chain setting again. Refer to Camshaft Timing Chain Adjustment .

38. Install the both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Intake) .

39. Fill the cooling system. Refer to Cooling System Draining and Filling (LDK/A20NHT) and Cooling System Draining and Filling (LBS/A20DTH) Cooling System Draining and Filling (LAU/A28NER) .

40. Install all spark plugs. Refer to Spark Plug Replacement .