59. Intake and Exhaust Camshaft, Bearing Cap, and Lash Adjuster Installation

Intake and Exhaust Camshaft, Bearing Cap, and Lash Adjuster Installation

Exhaust Camshaft Installation




1. Install the hydraulic lash adjusters into their bores in the cylinder head and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




2. Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).





Note: Used roller followers must be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced.

3. Position the roller followers on the tip of the valve stem and on the lash adjuster and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




4. When installing camshafts, ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.




5. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




6. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.




7. Install the exhaust camshaft with the notch on the front (1) at approximately the 7 o'clock position.
8. Install the camshaft caps and hand start the camshaft cap bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

9. Lubricate and tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 Nm (89 lb in).

Intake Camshaft Installation




1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




3. Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).





Note: Used roller followers must be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced.

4. Position the roller followers on the tip of the valve stem and on the lash adjuster and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




5. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.




6. Set the intake camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).




7. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.





Note: The number 1 cylinder must be at top dead center (TDC), crankshaft keyway at the 12 o'clock position.

8. Install the intake camshaft with the notch on the front at approximately the 5 o'clock position (2).
9. Install the camshaft caps and hand start the camshaft cap bolts.
10. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 Nm (89 lb in).





Note: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush.

* Ensure that all sealing material has been removed from the components, and the sealing surfaces are clean and free of contamination prior to applying the sealer.
* Install and align the rear cap within 20 minutes of applying the sealer.

Note: Apply the sealer to all locations centrally locating the bead on the rail.

* Run bead to 5.0 mm, dimension a, as shown.
* Where the cap ends on the perimeter rail, extend bead approximately 4.0 mm beyond edge of cap.
* Run bead, dimension c, 32 mm from the edge of the cylinder head as shown.
* Run beads, dimension b, 20 mm from edge of cylinder head as shown.

11. Apply a 2.5 mm bead of sealer to the cylinder head at the number 6 intake camshaft rear cap mating surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers).
12. Install the number 6 intake camshaft rear cap.

1. Tighten the cap bolts evenly to 5 Nm (44 lb in).
2. Tighten the cap bolts evenly to 10 Nm (89 lb in).
3. Back the cap bolts out 120 degrees.
4. Tighten the cap bolts evenly a final pass to 10 Nm (89 lb in).




13. Remove all excess sealing material from the fuel pump roller lifter bore (1), and ensure the bore is free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.
14. Remove all excess sealing material from the fuel pump assembly sealing surface (2).




15. Ensure that the opening plate sealing surface is clean and free of excess sealing material. Install the rear cylinder head opening plate and bolts and tighten to 10 Nm (89 lb in).