Removal and Replacement

Rocker Arm









Removal

1. Remove the engine from the vehicle. For additional information, refer to Engine Engine - Removal.

2. NOTE: Mark the location of the stud bolts.

Remove the RH 6 stud bolts, 5 bolts and valve cover.

- Clean and inspect the valve cover gasket. Install a new gasket if necessary.





3. Remove the RH high-pressure oil rail-to-valve cover gasket.





4. If replacing rocker arms on the LH side, remove the protective covering from the LH cylinder head.

5. Locate the dowel hole in the vibration damper.
- The hole is located between 2 of the 4 bolts that attach the damper to the front of the crankshaft.





6. Rotate the crankshaft until the dowel hole is at the 12 o'clock position.
- The No. 1 piston should be on the compression stroke. Wiggle the rocker on the No. 1 cylinder to verify both intake and exhaust rocker arms are able to move freely. If the intake and exhaust rocker arms do not move freely, rotate the crankshaft one complete revolution. The rocker arms for cylinders 1, 2, 7 and 8 are now positioned for service.





7. NOTE: If servicing all rocker arms, or any of the rocker arms for cylinders 1, 2, 7 and 8, the remainder of this procedure must be performed before rotating the crankshaft to prepare the engine-to-service cylinders 3, 4, 5 and 6.

If required, skip Step 8 and complete the rest of this procedure, for rocker arms on cylinders 1, 2, 7 and 8.

8. NOTE: All service for cylinders 1, 2, 7 and 8 must be completed before rotating the crankshaft to prepare the engine to service cylinders 3, 4, 5 and 6.

If not servicing cylinders 1, 2, 7 and 8 or if service to those cylinders has been completed, rotate the crankshaft one complete revolution to service the rocker arms for cylinders 3, 4, 5 and 6.

- Complete the rest of this procedure for rocker arms on cylinders 3, 4, 5 and 6.

9. Remove the crankcase-to-head tube(s).





10. NOTE: LH cylinder head shown, RH cylinder head similar.

NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support these components.

Remove the 9 bolts and the high-pressure oil rail.





11. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.

If the crankcase-to-head tube separated, using the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.





12. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.





13. NOTICE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.

Using the Injector Connector Release Tool, push the fuel injector electrical connector out of the rocker arm carrier.





14. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.

15. NOTICE: To prevent engine damage, do not use air tools to remove the fuel injectors.

NOTE: There is no need to drain the fuel rail.

NOTE: The bolt is part of the fuel injector hold-down assembly.

Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector.

- Remove and discard the O-ring seals and copper washer.





16. NOTE: Make sure the notch in the base is aligned in the hold-down clamp.

Insert the injector hold-down clamp into the Rocker Arm Service Tool base.





17. NOTICE: While centering the base between the 2 bridges, snug the hold-down bolt only. Do not tighten it or engine damage can occur.

Install the injector hold-down clamp and Rocker Arm Service Tool base in between the bridges as if installing a fuel injector.





18. NOTICE: Only use hand tools to compress the valve springs. Do not use power tools or engine damage can occur.

NOTE: If the rocker arm is severely worn, insert a small pry bar between the exhaust rocker arm and bridge to gain clearance by compressing the valves slightly.

Install the Rocker Arm Service Tool plate on top of the bridges with the small point of the plate in between the exhaust rocker and bridge. Install the Rocker Arm Service Tool bolt and compress the valve springs until the plate contacts the top of the tool base.





19. NOTE: When removing the rocker arm, be careful not to drop the ball from the fulcrum plate or rocker arm socket.

Disengage the rocker arm from the push rod. Then rotate the rocker arm out while compressing down on the rocker arm retaining clip.

- Remove and discard the rocker arm retaining clip.

- Repeat the step for the other rocker arm.





20. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install the push rods back in their original positions. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.

Remove the push rod.

- Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly. Install new push rods as necessary.

- Check the push rod for flatness by rolling them on a flat surface if not within specification. Install new push rods as necessary. For additional information, refer to Specifications.





21. With the rocker arms removed, remove the Rocker Arm Service Tool bolt and the Rocker Arm Service Tool plate to gain access to the valve bridges.





22. NOTE: Mark the location of the valve bridges before removing.

Remove the valve bridges.

- Inspect the valve bridges for wear or damage and install new as needed.





Installation

1. NOTE: Apply clean engine oil on the valve stems prior to installing the valve bridges.

Install the valve bridges.





2. Install the Rocker Arm Service Tool plate and bolt. Tighten the bolt until the plate contacts the top of the Rocker Arm Service Tool base.





3. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.

Apply clean engine oil to each end of the push rods and insert them into their respective positions.





4. Place a dab of multi-purpose grease in the fulcrum socket to hold the ball in place while installing the rocker arms.





5. NOTE: Apply clean engine oil to the top center of the valve bridges prior to installing the rocker arms.

Insert the rocker arm under the fulcrum and ball, rotate the rocker arm into place and position onto the push rod. Install a new rocker arm retaining clip.

- Repeat the step for the other rocker arm.





6. Remove the Rocker Arm Service Tool bolt and plate.
- Make sure the rocker arms remain in place and the fulcrum ball has not fallen out.





7. Remove the shop towels.

8. Remove the injector hold down and Rocker Arm Service Tool base.





9. NOTE: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and copper washer on the fuel injector.





10. NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.

Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly.

- Tighten to 35 Nm (26 lb-ft).





11. NOTICE: Be sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker arm carrier.





12. NOTICE: Using the bolts to push the high-pressure oil rail into the fuel injectors can damage the fuel injectors and high-pressure oil rail.

NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.

Position the high-pressure oil rail on the injectors.

- Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.

- Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high pressure oil rail. Install the guide studs 6 to 7 turns.

- Manually press the high-pressure oil rail into the fuel injectors.

- Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.

- Loosely install the 6 bolts.





13. Install the remaining bolts and tighten.
- Remove the 3 guide bolts.

- Loosely install the 3 remaining bolts.

- Tighten the 9 bolts in the sequence shown to 13 Nm (115 lb-in).





14. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube if necessary. Install the crankcase-to-head tube(s).
- Tighten to 82 Nm (60 lb-ft).





15. If removed, cover the LH cylinder head with an appropriate covering.

16. Install the RH high-pressure oil rail-to-valve cover gasket.





17. NOTICE: To prevent engine damage, do not use air-powered tools when installing the valve cover.

Position the RH valve cover gasket. Install the RH valve cover, 6 stud bolts and 5 bolts.

- Tighten to 9 Nm (80 lb-in).





18. Install the engine in the vehicle. For additional information, refer to Engine Engine - Installation.