Camshaft: Service and Repair

CAUTION: Do not rotate the engine with the camshaft(s) disconnected.


REMOVE
- Remove camshaft covers. Refer to CAMSHAFT COVER.
- Remove the rubber grommet from the front of the timing cover.

Timing Chain Tensioner Retracting Tool:

- Insert JD 50 (Release Tool) through the timing cover, and release the locking catch on the timing chain tensioner.
- Fit JD 50 (Chain Tension Retainer) and retract the timing chain tensioner until the locking catch is engaged.
- Remove JD 50.

Camshaft Timing Gauge:

- Rotate the engine to the cam removal position until Timing Gauge C 3993 can be inserted into the recess in the LH camshaft.
- Note the two uppermost camshaft sprocket retaining bolts and remove Timing Gauge C 3993.
- Rotate the engine until the two LOWER camshaft sprocket retaining bolts become accessible. Push back the lock tabs and remove the two retaining bolts.
- Rotate the engine to the camshaft removal position and refit Timing Gauge C 3993.

Sprocket Bolts And Retaining Tool:

- Remove the remaining two camshaft sprocket bolts and fit JD 40.
- Gradually loosen each camshaft cap securing nut two turns at a time until the valve springs are fully relaxed.

L/H Camshaft:

- Note the cap to carrier relationship. Remove the nuts and washers and lift-off the bearing caps.
- Remove the camshaft.
- Clean all components thoroughly.
- Examine all component parts for wear and damage. Replace worn or damaged components as necessary.

REFIT
- Be sure that all oilways are clear.
- Lubricate the camshaft journals with clean engine oil.
- Fit the replacement camshaft to the camshaft carrier, using C 3993 to position the camshaft correctly.
- Fit the bearing caps, washers and securing nuts. Progressively tighten the securing nuts to the correct torque, working from the center outwards.
- Check that Timing Gauge C 3993 is in position. Engage the camshaft sprocket to the camshaft, fit and tighten one retaining bolt.
- Remove JD 40 and C 3993.
- Rotate the engine and fit the remaining sprocket retaining bolts. Lock over the tabs.
- Repeat the procedure for the RH camshaft.
- Fit JD 50 (Chain Tension Retainer) and raise the timing chain tensioner slightly.
- Insert JD 50 (Release Tool) through the timing cover. Release the locking catch and allow the tensioner to expand.
- Remove both Service Tools and refit the rubber grommet to the front of the timing cover.
- Adjust the valve clearances. Refit the cam covers and induction manifolds. Evacuate and charge the air conditioning system.
- Refit the air cleaner.
- Reconnect the battery.


VALVE CLEARANCE
Inlet 0.031 to 0.036 mm (0.012-014 in)
Exhaust 0.031 to 0.036 mm (0.012-O14 in)


SERVICE TOOLS
Timing Gauge C 3993
Camshaft Sprocket Retainer JD 40
Chain Tension Retainer/Release Tool JD 50

TORQUE FIGURES
Bearing caps to carrier 11-13.5 Nm
Camshaft sprocket to camshaft 23-27 Nm
Camshaft cover 77 Nm
EGR valve to throttle housing 9.5-12 Nm
Elbow to inlet manifold 12.2 Nm
Hose clips 2.5 Nm
Inlet manifold to cylinder head (nuts) 23-27 Nm
Inlet manifold to cylinder head (bolts) 23-27 Nm
Silencer to compressor union 34 Nm