Valve Mechanism Cover Base - Remove and Install


Valve Mechanism Cover

Removal Procedure


Disconnect the breather hose from the separator for the crankcase breather.
Remove:
- the setscrews (1) from the valve mechanism cover (2).
- the valve mechanism cover (2) from the valve mechanism cover base.
- the joint (3) from the valve mechanism cover (2). Discard the joint. If necessary, remove the separator for the crankcase breather from the valve mechanism cover base.

Installation Procedure

Thoroughly clean all surfaces of the valve mechanism cover. Clean the mating surfaces of the valve mechanism cover base.
If necessary, install the separator for the crankcase breather (not shown) to the valve mechanism cover (2). Install a new joint (3) to the valve mechanism cover (2). Ensure that the joint is fully seated into the groove of the valve mechanism cover.


Ensure that the harness assemblies (5) are not in contact with the rocker arms of the valve mechanism cover base. Position the valve mechanism cover (2) onto the valve mechanism cover base (4). Ensure that the harness assemblies (5) are not trapped during the assembly procedure. Install the setscrews (1).


Tighten the setscrews in the numerical sequence that is shown in Illustration. Tighten the setscrews to a torque of 9 N·m (79 lb in). Connect the breather hose to the separator for the crankcase breather (not shown).


Valve Mechanism Cover Base

Removal Procedure

Remove:
- the valve mechanism cover.
- the fuel injection lines.


Place a temporary identification mark on the connections (1) for the harness assembly (4). Use a deep socket to remove the connections (1) from the electronic unit injectors (2). If necessary, follow steps to remove the harness assemblies (4) from the valve mechanism cover base (6). Cut the cable ties (3). Disconnect the plug (7) from the harness assembly (4). Use Tooling to remove the circlip (5). From the outside of the valve mechanism cover base (6), push the harness assembly (4) inward. Withdraw the harness assembly from the valve mechanism cover base (6).
- the O-ring seal (8) from the harness assembly (4). Discard the O-ring seal. Repeat steps to remove the remaining harness assemblies.


Loosen the isolated screws (9) in reverse numerical order. Refer to illustration. This will help prevent distortion of the valve mechanism cover base (6).


- valve mechanism cover base (6) from the cylinder head.
- the isolated setscrews (9) from the valve mechanism cover base (6).
- the seal (10) from the valve mechanism cover base (6). Discard the seal.

Installation Procedure

Clean the valve mechanism cover base. Ensure that the seal surfaces are free from damage.


Install:
- the seal (10) to the valve mechanism cover base (6). Ensure that the seal (10) is seated correctly in the groove in the machined face of the valve mechanism cover base (6).
- the isolated screws (9) to the valve mechanism cover base (6).


Position the valve mechanism cover base (6) on the cylinder head. Tighten the isolated screws (9) to a torque of 9 N·m (79 lb in) in the sequence that is shown in illustration.


If necessary, install the harness assemblies for the electronic unit injectors. Follow steps in order to install the harness assemblies for the electronic unit injectors. Ensure that the harness assembly (4) and the bore in the valve mechanism cover base (6) are clean and free from damage. Replace any damaged components. Use Tooling to lubricate a new O-ring seal (8). Install the new O-ring seal (8) onto the harness assembly (4). From the inside of the valve mechanism cover base (6), push the harness assembly (4) into the valve mechanism cover base (6). Use Tooling to install the circlip (5). Connect the plug (7) to the harness assembly (4). Use a deep socket to connect the harness (4) to the electronic unit injectors (2). Use Tooling to tighten the connectors (1) to a torque of 2.4 N·m (21 lb in).
- a new cable tie (3) to the harness assembly (4). Ensure that cable ties to OE specification are used. Repeat steps for the remaining harness assemblies (4).
- new fuel injection lines.
- the valve mechanism cover.