Rocker Arm
Rocker ArmSpecial Tool(s):
Material:
Removal
1. Remove the engine from the vehicle.
2. NOTE: Mark the location of the stud bolts.
Remove the RH stud bolts, 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. You are now positioned to service the rocker arms for cylinders 1, 2, 7 and 8.
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 you are 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.
^ Remove and discard the D-ring seals.
10. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
Remove the 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 special tool, remove the lower crankcase-to-head tube.
^ Remove and discard the D-ring seal.
12. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
13. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
14. CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing serve engine damage.
NOTE: There is no need to drain the fuel rail.
Remove the bolt, the fuel injector hold down and the fuel injector.
15. NOTE: Make sure the notch in the base is aligned in the hold-down clamp.
Insert the injector hold-down clamp into the special tool base.
16. CAUTION: 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 assembly in between the bridges as if you are installing an injector.
17. CAUTION: 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 special tool plate on top of the bridges with the small point of the plate in between the exhaust rocker and bridge. Install the special tool bolt and compress the valve springs until the plate contacts the top of the tool base.
18. 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.
19. CAUTION: 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.
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.
20. With the rocker arms removed, remove the special tool bolt and the special tool plate to gain access to the valve bridges.
21. Remove and discard the valve bridges.
Installation
1. CAUTION: Install new O-ring seals on the crankcase-to-head tube. It requires several hours after installation for the O-ring seals to relax back to their original size. If the tube assembly is installed before the O-rings seals have relaxed, damage to the O-ring seals can occur.
Install new O-ring seals on the crankcase-to-head tube assemblies.
2. NOTE: Apply clean engine oil on the valve stems prior to installing the valve bridges.
Install the new valve bridges.
3. Install the special tool plate and bolt. Tighten the bolt until the plate contacts the top of the tool base.
4. CAUTION: 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.
Apply clean engine oil to each end of the push rods and insert them into their respective positions.
5. Place a dab of multi-purpose grease in the fulcrum socket to hold the ball in place while installing the rocker arms.
6. NOTE: Apply clean engine oil to the top center of the valve bridges prior to installing the rocker arms.
NOTE: Always install a new rocker arm retaining clip with the same color clip.
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.
7. Remove the special tool bolt and plate.
^ Make sure the rocker arms remain in place and the fulcrum ball has not fallen out.
8. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
9. Remove the injector hold down and special tool base.
10. CAUTION: 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.
11. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
Install the fuel injector, the fuel injector hold down and bolt.
^ Tighten to 35 Nm (26 ft. lbs).
12. CAUTION: 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.
13. CAUTION: 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.
14. 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 (10 ft. lbs).
15. Apply clean engine oil and install the crankcase-to-head tube.
^ Tighten to 82 Nm (60 ft. lbs).
16. If removed, cover the LH cylinder head with an appropriate covering.
17. Install the RH high-pressure oil rail-to-valve cover gasket.
18. CAUTION: 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, stud bolts and bolts.
^ Tighten to 9 Nm (80 inch lbs).
19. Install the engine in the vehicle.