NOTE: Using valve service tools #9307, screw
retaining fork into threaded edge of cylinder head
and position thrust piece vertically at the top of
each exhaust valve spring retainer. Use the cam
bearing cap threaded holes to position service tool
for installation of intake valve spring retainers.
NOTE: Ensure that the valve keepers are seated
properly.
(9) Compress valve an d i n st all va lve collat es (Fig.
26).
CAUTION: Make sure the crankshaft lock is in posi-
tion and properly secured for each cylinder being
serviced. Failure to do so may result in damage to
the vehicle or personal injury.
(10) Repeat pr ocedu re for each cylinder as neces-
sary.
(11) Remove special tooling from cylin der head.
(12) Posit ion piston of #1 cylinder t o ignit ion TDC.
(13) Install camsh afts an d check ba sic posit ion
(Refer t o 9 - ENGINE/CYLINDER HEAD/CAM-
SH AFT(S) - INSTALLATION).
(14) Install top gu ide rail (Refer to9-ENGINE/
CYLINDER H EAD - INSTALLATION).
(15) Install front cover a t cylinder hea d (Refer to 9
- ENGINE /CYLINDER H EAD - INSTALLATION).
(16) Install timing ch ain ten sioner with new gas-
ket (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CH AIN AND SPROCKE TS - INSTALLATION)
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
(18) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJ ECTION/FUEL INJ ECTOR -
INSTALLATION).
(19) Reconn ect nega tive battery cable.
(20) Star t the engine, allow to wa rm, tu rn engin e
off and inspect for leaks. Care must be ta ken to
observe the fuel syst em wa rnin g (Refer t o 14 - F UEL
SYSTEM - WARNING)
(21) Install engine cover (Refer t o9-ENGINE
COVER - INSTALLATION).
INSTALLATION - VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.
NOTE: Inspect all valves, springs and retainers for
wear or damage. Replace as necessary.
(1) In st all valves in their original position in the
cylinder head.
(2) In st all lower valve spring retainer.
(3) In st all valve stem sea l.
(4) In st all valve spring.
(5) In st all valve spring retainer.
NOTE: Using tool, screw retaining fork into
threaded edge of cylinder head and position thrust
piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated
properly.
(6) Usin g a suita ble va lve spring compressor, com-
press valve spring and inst all valve keepers.
(7) Repeat st eps 3 t hrough 7 for each valve as nec-
ess a r y.
(8) Remove va lve a ssembly from cylin der head.
(9) In st all cylinder hea d on engin e block (Refer to
9 - ENGINE/CYLINDE R HEAD - INSTALLATION).
(10) Install glow plugs (Refer t o 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
(11) Connect nega tive battery cable.
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(12) Star t en gine a nd ch eck for leaks. Car e must
be ta ken to observe the fuel system warn ing (Refer to
14 - FUEL SYSTEM - WARNING)
(13) Install engine cover (Refer t o9-ENGINE
COVER - INSTALLATION).
EN GI N E BLOCK
STAN DARD PROCEDU RE
STANDARD PROCEDURE - REPLACING ENGINE
CORE AND OIL GALLERY PLUGS
Usin g a blunt tool such a s a drift and a ham mer,
st rike t he bottom edge of the cup plug. Wit h the cu p
plug rot ated, gr asp fir mly with plier s or oth er suit-
able tool and rem ove plug (F ig. 30).
VA ENGINE 9 - 37
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