Camshaft and Rocker Arm
CAMSHAFTS AND ROCKER ARMSREMOVAL AND INSTALLATION
Removal Steps 1-11:
INSPECTION
CAMSHAFT
1. Measure the cam height.
NOTE: The camshaft identification mark is stamped on the rear end of camshaft.
ROCKER ARM
1. Check the roller surface. If any dent, damage or seizure is evident, replace the rocker arm.
2. Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm.
3. Check the inside diameter. If damage or seizure is evident, replace the rocker arm.
LASH ADJUSTER LEAK DOWN TEST
When the lash adjuster is set on a tester, remove the adjusting screw of the tester and adjust it to the height of the lash adjuster as shown in the illustration.
CAUTION:
1. The lash adjuster is a precision part. Keep it free from dust and other foreign matters.
2. Do not disassemble the lash adjusters.
3. When cleaning the lash adjusters. Use clean diesel fuel only.
1. Immerse the lash adjuster in clean diesel fuel.
2. While lightly pushing down the inner steel ball using a small wire, move the plunger up and down tour or five times to bleed air. Use of the retainer facilitates the air bleeding of a rocker arm mounted type lash adjuster.
3. Remove the small wire and press the plunger. If the plunger is hard to be pushed in, the lash adjuster is normal. If the plunger can be pushed in all the way readily, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster.
CAUTION: Upon completion of air bleeding, hold the lash adjuster upright to prevent inside diesel fuel from spilling.
4. After air bleeding, set the lash adjuster on the special tool (Leak down tester).
5. After the plunger has gone down somewhat (0.2-0.5 mm), measure time taken for it to go down 1 mm. Replace if the measured time is out of the specification.
Standard value: 4-20 seconds/1 mm (0.04 in.) [Diesel fuel at 15-20 °C (59-68 °F)]
INSTALLATION SERVICE POINTS
A LASH ADJUSTER INSTALLATION
1. Immerse the lash adjuster in clean diesel fuel.
2. Using a small wire, move the plunger up an down 4 to 5 times while pushing down lightly on the check ball in order to bleed out the air.
B CAMSHAFT INSTALLATION
1. Apply engine oil to journals and cams of the camshafts.
2. Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the exhaust one. The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.
3. Install the crankshaft sprocket B or spacer and flange to an end of the crankshaft, and turn the crankshaft until the timing marks are lined up, setting No.1 cylinder to the TDC.
4. Set the camshafts so that their dowel pins are positioned at top.
C BEARING CAP INSTALLATION
1. According to the identification mark stamped on top of each bearing cap, install the caps to the cylinder head. Only "L" or "R" is stamped on No.1 bearing cap. Cap No. is stamped on No.2 to No.5 bearing caps. No.6 bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
2. Tighten the bearing caps in the order shown by torquing progressively in two to three stages Tighten to the specification in the final sequence.
3. Check to ensure that the rocker arm is held in position on the lash adjuster and valve stem end.
D CAMSHAFT OIL SEAL INSTALLATION