Removal and Replacement

CAMSHAFT(S)

REMOVAL
1. Disconnect negative battery cable.
2. Remove engine cover.

WARNING: (Refer to FUEL SYSTEM WARNING)

3. Remove high pressure lines and injectors.
4. Remove cylinder head cover.

NOTE: Rotate engine at the crankshaft only. DO NOT rotate the engine at the camshaft. DO NOT rotate the engine backward.

5. Position piston of cylinder #1 to ignition TDC.





6. Lock inlet camshaft (Fig. 20).
7. Remove timing chain tensioner.

NOTE: The lower portion of the cylinder head front cover is sealed with RTV sealant. Carefully tug front cover after bolt removal to loosen from cylinder head.

8. Remove cylinder head front cover.
9. Remove top side rail.

CAUTION: For all work in which the crankshaft should not rotate, secure camshaft gear to timing chain.

10. Mark camshaft sprocket relative to timing chain.
11. Unbolt camshaft sprocket from exhaust camshaft.

NOTE: Note the position of dowel pin for camshaft sprocket alignment during reassembly.

12. Remove camshaft sprocket.

CAUTION: Camshaft bearing caps must remain in proper order and position.

NOTE: Slacken the bolts of the camshaft bearing caps evenly in steps of one turn until the back pressure is eliminated. Camshafts must not be twisted when slackening the camshaft bearing caps.

13. Paint mark or scribe each camshaft bearing cap, identifying which camshaft and which position.
14. Remove the camshaft bearing caps at exhaust camshaft bearing cap #1, #3,#4 and #6 in sequence.
15. Remove the camshaft bearing caps at intake camshaft bearing cap #1, #3,#4 and #6 in sequence.
16. Slacken the exhaust camshaft bearing cap bolts individually at the #2 cap then the #5 cap in steps of one revolution until the back pressure is removed.
17. Slacken the intake camshaft bearing cap bolts individually at the #2 cap then the #5 cap in steps of one revolution until the back pressure is removed.





18. Remove the inlet and exhaust camshafts (Fig. 21).

NOTE: Inspect camshaft for wear or damage. Also inspect the camshaft end cover for wear or damage, replace camshaft as necessary.

INSTALLATION

CAUTION: The camshafts are sensitive to fracturing. Ensure they are installed free of stress.

CAUTION: Pay attention to assignment of camshafts. Camshaft code numbers are visible on the thrust collar of the axial bearing.

CAUTION: Oil bucket tappets and camshaft bearing points. Inspect ease of operation of bucket tappets.

1. Install inlet and exhaust camshafts.

CAUTION: Install camshafts so that the two holes in camshaft sprockets are positioned opposite and the markings of the camshaft and camshaft bearing cap are aligned.

2. Align inlet and exhaust camshafts at axial bearing.

NOTE: Pay attention to markings on camshaft bearing caps.

CAUTION: Do not rotate engine counter clockwise.

3. Position the piston of cylinder # 1 to ignition TDC.

NOTE: Pay attention to markings on camshaft bearing caps and follow the tightening procedure below.





4. Install the #2 and #5 Exhaust cam bearing caps (Fig. 22).
5. Install the #2 and #5 Intake cam bearing caps (Fig. 22).
6. Tighten each of the #2 and #5 Intake and Exhaust bearing cap bolts evenly to 9 Nm (80 inch lbs.) in steps each of 1 revolution (Fig. 22).





7. Install the remaining Intake and Exhaust cam bearing caps and tighten them evenly to 9 Nm (80 inch lbs.) in steps each of 1 revolution (Fig. 23).

NOTE: The piston of cylinder #1 must be positioned at ignition TDC when the inlet camshaft is locked.

8. Insert locking pin through the first camshaft bearing cap into the whole in the camshaft sprocket.

NOTE: Do Not use old camshaft sprocket bolts.

9. Fit camshaft sprocket with timing chain fitted on, onto exhaust camshaft paying attention to position of dowel pin. Tighten bolt to 18 Nm (159 inch lbs.).
10. Install timing chain tensioner.
11. Inspect/Set basic position of camshafts.
12. Insert slide rail and bolt the driver into the inlet camshaft. Tighten bolt driver to 50 Nm (37 inch lbs.).
13. Install front cover at cylinder head.
14. Install cylinder head cover.

NOTE: Refer to the appropriate injector servicing procedures for cleaning of injectors and recesses.

15. Clean and install injectors.
16. Reconnect negative battery cable.

WARNING: (Refer to FUEL SYSTEM WARNING).

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. 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.

17. Start engine and inspect for leaks. Care must be taken to observe the fuel system warning.
18. Install engine cover.