@Faheem here ya go, not so bad as removing the head. found this, this is our issue.
Situation 2
Binding HVA element.
Cause
An HVA element which is binding (element stuck in the extended position) will not allow a valve (intake or exhaust) to seat properly causing valve seat leakage.
This type of HVA failure may not cause a tapping/rattling noise but the customer complaint may be, "engine runs rough during the warm up phase and runs good when warmed up" and/or the "Check Engine" lamp is on.
If the "Check Engine" lamp is illuminated due to a binding HVA element(s) one or more misfire fault codes may be set in the Engine Control Module (ECM/DME).
Note: Basic troubleshooting should be performed First before checking for a binding HVA element to eliminate all other possible factors/components which could set the misfire faults such as low fuel level, a faulty spark plug, etc.
Troubleshooting Tips:
• If there is a binding HVA element in one or more cylinders as described above a misfire fault can typically be reproduced in the affected cylinders) by duplicating the conditions in which the misfire occurred according to the DME/ECM fault code description i.e., at engine temperature = X, engine speed = X, etc.
• A binding HVA element which is causing a misfire in one specific cylinder will not "move" to an other cylinder and will always cause a misfire fault in the affected cylinder.
• Performing the "Smooth-Running" test (found in the DME control unit functions section of DIS) will assist in pin pointing a cylinder with a binding HVA element.
A cylinder with a binding HVA element will indicate a high reading when compared to the other good cylinders.
• Since a binding HVA element may in some cases be intermittent (engine only runs rough when cold) if a cylinder leak down check is used for troubleshooting this should be performed when the problem exists, for example: compare the cylinder leakage rates to each other with a cold engine to determine the cylinder with the extreme leakage rate.
A cylinder with a binding HVA element will indicate a leakage rate above 15%.
Remove suspected HVA elements and visually inspect.
• A binding HVA element will typically have a high pressure piston (located in the centre of the HVA element body) which extends out approximately 3 mm further when compared to the other HVA elements removed from the cylinder head.
Replace any binding HVA element(s) and check others for extreme wear (deep grooves, scratches, etc.) which may also need to be replaced.
Note: Always reinstall used HVA elements in the same bore which they were removed from. This prevents possible binding due to different wear patterns between the bore in the HVA housing and HVA element.