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PRE-RELEASE

Valve Stem Oil Seal and Valve Spring Replacement

Valve Stem Oil Seal and Valve Spring Replacement



Special Tools

• EN-958 Installation Tool

• EN-6625 Flywheel Holder

• EN-6086 Basic Kit, Spring and Wedge Replacer

• EN-840 Pliers/Remover

• EN-889 Automatic Valve Spring Lever


For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure


1. Remove both camshafts. Refer to Camshaft Replacement (Exhaust-LLU/A16LET) Camshaft Replacement (Intake-LLU/A16LET) Camshaft Replacement (Exhaust) .

2. Remove the spark plugs. Refer to Spark Plug Replacement .

Note

180 degrees offset to marking ignition TDC cylinder number 1.


3. Make alignment mark on the toothed belt drive belt.

4. Turn the crankshaft to ignition TDC marking, cylinder number 1.

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

6. Block the crankshaft.

7. Install EN-6625 flywheel holder (1) to the engine block (2).


8. Lower the vehicle by its full height.

9. Install the supports.

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


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


12. Install the second support to the mounting shaft.

13. Install the lever arm bracket to the cylinder head.

14. Attach the EN-6086-15 pneumatic adapter (1).


14.1. Attach the adapter to cylinder number 1.

14.2. Apply compressed air to cylinder number 1.

15. Attach the EN-6086-7 lever arm (3).


15.1. Assemble the lever arm with the EN-6086-8 joint (1) and the EN-6086-11 removable head (2).

Note

Removal head must point toward the intake side.


15.2. Slide assembly on installation shaft over the 1st cylinder.

16. Remove the intake valve springs, 1st cylinder.

Note

Removal head must be positioned vertically over the valve stem.


16.1. Carefully push the valve springs down using the EN-6086-7 lever arm.

Note

Observe the correct assignment.


16.2. Remove the valve keepers.

16.3. Remove the valve head and the valve springs.

17. Remove the valve stem seals with the EN-840 puller (1).


18. Install the valve stem seals.

18.1. Coat the valve stem with engine oil.

18.2. Connect the new valve stem seals onto valve stem.

18.3. Using the EN-958 installer , drive home to limit stop.

19.
Note

Follow manufacturer instructions.



20. Complete the EN-6086-200-1 assembly head.

• Use the EN-6086-200-10 thrust piece.

• Put together the assembly head consisting of mount (1), fixing sleeve (2), thrust piece (3), spring (4), screw fixing (5) and lever mount (6).

21. Install the intake valve springs, 1st cylinder.


• Insert the valve springs and valve head.

Note

Insert the valve cotters with the tapered end toward the valve.


• Insert the valve cotters (1) in the EN-6086-200-1 assembly head.

- Slide the plastic clamping sleeve (2) in the direction of the lever arm mount.

- Push the plastic clamping sleeve toward the valve.

Note

Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.


• Attach the assembly head to the lever arm.

• Carefully push the valve spring down using the EN-6086-7 lever arm.

Note

Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.


22. Inspect installation position.

23. Inspect seating of the valve keepers (visual inspection).

24. Transfer the EN-6086-7 lever arm.

24.1. Remove the lever arm.

24.2. Detach the assembly head.

Note

Removal head must point toward the exhaust side.


24.3. Attach the removal head.

24.4. Install the lever arm.

25. Remove the exhaust valve springs, 1st cylinder.

25.1. Carefully push the valve springs down using the EN-889-12 lever arm.

Note

Removal head must be positioned vertically over the valve stem.


25.2. Remove the valve keepers

Note

Observe the correct assignment.


25.3. Remove the valve head and the valve springs.

26. Replace the valve stem seals.

26.1. Pull off using the EN-840 remover.

26.2. Coat the valve stem with engine oil.

26.3. Connect the new valve stem seals onto the valve stem.

26.4. Using the EN-958 installer , drive home to limit stop.

27. Attach the EN-6086-7 lever arm.

• Insert the valve springs and valve head.

• Insert the valve wedges in the EN-889-2 assembly head.

Note

Insert the valve cotters with the tapered end toward the valve.


- Push the plastic clamping sleeve toward the lever arm mounting.

- Push the plastic clamping sleeve toward the valve.

Note

Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.


• Attach the assembly head to the lever arm.

Note

Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.


• Carefully push the valve spring down using the EN-889-12 lever arm.

28. Inspect installation position.

29. Inspect seating of the valve keepers (visual inspection).

30. Transfer the EN-6086-15 pneumatic adapter.

30.1. Interrupt the compressed air feed.

30.2. Remove the adapter from cylinder number 1.

30.3. Install the adapter to cylinder number 4.

30.4. Apply compressed air to cylinder number 4.

31. Replace the valve stem seal of cylinder 4 by analogy with step 14 to step 23.

32. Remove the EN-6086-15 pneumatic adapter.

32.1. Interrupt the compressed air feed.

32.2. Remove the adapter from cylinder number 4.

33. Raise the vehicle by its full height.

34. Remove the EN 6625 holder.

35. Set the crankshaft to ignition TDC of cylinder 3.

Note

Alignment marking on toothed belt drive wheel must align with marking on rear toothed belt cover.


36. Turn crankshaft evenly by 180 degrees.

37. Block the crankshaft.

38. Install EN-6625 holder to the engine block.

39. Lower the vehicle by its full height

40. Replace the valve stem seal of cylinders 2 and 3 by analogy with step 7 to step 23.

41. Remove the EN-6086-15 pneumatic adapter.

41.1. Interrupt the compressed air feed.

41.2. Remove the adapter from cylinder number 3.

42. Remove the EN-6086 automatic valve spring lever.

42.1. Release the installation shaft.

42.2. Remove both supports with the installation shaft.

42.3. Remove the installation head from the lever arm.


Installation Procedure


1. Raise the vehicle.

2. Remove EN-6625 holder from the engine block.

• Detach the screwed connection.

• Tighten the bolted connection.

• Install new nuts.

3. Set the engine to 60 degrees (measurement l) before TDC.


4. Set the crankshaft in direction of engine rotation to 60 degrees (measurement l) before TDC.

5. Install the spark plugs. Refer to Spark Plug Replacement .

6. Install both camshafts. Refer to Camshaft Replacement (Exhaust-LLU/A16LET) Camshaft Replacement (Intake-LLU/A16LET) Camshaft Replacement (Exhaust) .


PRE-RELEASE