Removal and Replacement

ROCKER ARMS AND CAMSHAFT

REMOVAL AND INSTALLATION

Removal Steps 1-13:

INSPECTION

CAMSHAFT




1. Measure the cam height.






NOTE: The camshaft identification mark is stamped on the opposite end of the camshaft sprocket side







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

CAUTION:
1. The lash adjuster is a precision part. Keep it free from dust and other foreign matter.
2. Do not disassemble lash adjuster.
3. When cleaning lash adjuster, use clean diesel fuel only.




1. Immerse the lash adjuster in clean diesel fuel.
2. While lightly pushing down inner steel ball using the small wire, move the plunger up and down four or five times to bleed air.

Use of the retainer helps facilitate the air bleeding of the 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 lash adjuster upright to prevent inside diesel fuel from spilling.




4. After air bleeding, set lash adjuster on the special tool (Leak down tester).




5. After plunger has gone down somewhat (0.2-.5 mm), measure time taken for it to go down 1 mm. Replace if measured time is out of specification.

Standard value: 4-20 seconds/1 mm (0.04 in.) (Diesel fuel at 15-20 °C (59-68 °F)]

REASSEMBLY SERVICE POINTS

A CAMSHAFT INSTALLATION (DOHC)




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.

E BEARING CAPS INSTALLATION (DOHC)




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 two to three times by torquing progressively.
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.




F LASH ADJUSTED INSTALLATION
1. Immerse the lash adjuster in clean diesel fuel.
2. Using a small wire, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air.
3. Insert the lash adjuster to rocker ann, being careful not to spill the diesel fuel. Then use the special tool to prevent adjuster from falling while installing it.




H CAMSHAFT OIL SEAL INSTALLATION