CAMSHAFT AND CAMSHAFT GEAR CLEANING AND INSPECTION

INSPECTION

1. Wash the camshaft in a suitable solvent using a soft bristle brush.

2. Visually inspect camshaft. If any lobes are scuffed, scored or cracked, replace camshaft.

3. Beyond visual inspection, evaluate camshaft journal and lobe condition using a micrometer as follows:

a. Inspect camshaft journal for wear. Using a micrometer, measure camshaft journal diameter (see
"SPECIFICATIONS" ). If journals are worn beyond limits, replace the camshaft.

b. Check camshaft lobe wear using a micrometer as follows: ( Figure 5.23 )

c. Measure across (A-D) and across (B-C). Subtract (B-C) from (A-D). This will give cam lobe lift (see
( "SPECIFICATIONS" ). Replace camshaft when cam lobe wear exceeds specifications.

4. Visually inspect thrust plate wear, cracks or distortion. Use a micrometer to measure thrust plate thickness
(see "SPECIFICATIONS" ). Replace thrust plate if worn, damaged or if excessive end play is measured, as
previously described.

5. Visually inspect camshaft drive gear for worn or damaged teeth. Inspect the timing disk plate.
CAMSHAFT ASSEMBLY

ASSEMBLY

1. Assemble the camshaft, thrust plate, camshaft gear and timing disk plate as follows:

a. Support the camshaft in an appropriate arbor press.

b. Place the thrust plate on the keyway end of the camshaft against the bearing journal.

c. Insert the woodruff key into the keyway.

NOTE: Use a thermomelt stick, available at any welding supply house, to determine temperature.

d. Press camgear onto camshaft.

Figure 5.23 Check Camshaft Lobe Wear
ASSEMBLY OF CAMGEAR ONTO CAMSHAFT

NOTE: HEATING A CAMSHAFT GEAR BEYOND 177°C (350° F) WILL CAUSE IT TO TURN BLUE . ANY
CAMSHAFT GEAR WHICH HAS TURNED BLUE CANNOT BE REUSED.

1. IF ONLY the camgear was removed, perform the following:

a. Heat the camshaft gear in an oven to 149-177° C (300-350° F).

NOTE: 1. BE SURE TO USE WELDING GLOVES.

2. CAMSHAFT GEAR SHOULD SLIDE ONTO CAMSHAFT WITH SLIGHT HAND PRESSURE. DO NOT
FORCE CAMGEAR.

b. Use welding gloves to install the heated camshaft gear. Remove camgear assembly from oven. BE
SURE to align the camgear timing marks with the upper idler gear and install onto camshaft with timing
marks showing. HOLD camshaft gear on camshaft until it tightens as it cools (approximately 30 seconds,
Figure 5.24 ).
CHECKING CAMSHAFT END PLAY

Attach an indicator dial and check camshaft end play ( Figure 5.25 ). If there is excessive end play, the
camshaft has probably slipped back. Remove the camgear and pull the camshaft forward. Repeat step 1. Refer
to "SPECIFICATIONS" .
CAMSHAFT BUSHING INSPECTION

INSPECTION

1. Inspect the four (4) camshaft bushings for wear and proper running clearance as follows:

a. Using a micrometer, measure camshaft bushing journal diameter at two (2) locations, 90° apart and
record readings.

b. Using a telescoping gauge ( OEM1022 ) and micrometer, measure the camshaft bushing I.D. with
bushing installed in the crankcase. Record the readings.

Figure 5.24 Installing Camgear Onto Camshaft

Figure 5.25 Check Camshaft End Play
 c. Subtract the readings obtained in steps 1a and b, to determine running clearance.

d. If maximum allowable running clearance is exceeded (see "SPECIFICATIONS" ), replace the camshaft
bushings using the camshaft bushing remover and installer ( ZTSE2893C ).

NOTE: WHEN SERVICING THE CAMSHAFT BUSHINGS, THE CRANKSHAFT AND MAIN BEARING MUST
BE REMOVED FROM THE CRANKCASE TO AVOID DEBRIS CONTAMINATION.
CAMSHAFT BUSHING REMOVAL

REMOVAL

1. Use the camshaft bushing service set ( ZTSE2893C ) to remove the camshaft bushings. Refer to Figure
5.26 .

NOTE: ZTSE2893C includes:

Puller screw

Expanding mandrel

Puller screw extension

Expanding collate

Pulling nut

Back-up nut

Thrust bearing
 Figure 5.26 Camshaft Bushing Service Set Components

NOTE: The four camshaft bushings have the same inside diameter but the outside diameter and widths
of each bushing are different, as is the crankcase bore into which each bushing fits. Refer to the chart
below.

NOTE: BECAUSE OF THE DIFFERENT SIZE OUTSIDE DIAMETERS OF THE BUSHINGS, THE ORDER OF
REMOVAL IS LIMITED AS FOLLOWS: REMOVE THE FRONT AND REAR BUSHINGS FIRST. THEN
REMOVE THE TWO INTERMEDIATE BUSHINGS THROUGH THE FRONT OF THE CRANKCASE.

CAMSHAFT BUSHING CHART

BUSHING BORE BUSHING O.D. DIAMETER IN BUSHING
BUSHING POSITION CRANKCASE WIDTH

Front 63.665 mm 63.550 mm (2.5020 25.4 mm (1.00

(2.5065 in.) in.) 63.512 mm in.)
 63.627 mm (2.5005 in.)
(2.5050 in.)

Intermediate/Front 63.627 mm 63.042 mm (2.4820 18.0 mm

(2.4865 in.) in.) 63.004 mm (0.709 in.) 17.5
63.157 mm (2.4805 in.) mm (0.689 in.)
(2.4850 in.)

Intermediate/Rear 62.649 mm 62.534 mm (2.4620 18.0 mm

(2.4665 in.) in.) 62.611 mm (0.709 in.) 17.5
62.611 mm (2.4605 in.) mm (0.689 in.)
(2.4650 in.)

Rear 62.141 mm 62.026 mm (2.4420 18.7 mm

(2.4465 in.) in.) 61.988 mm (0.740 in.) 16.7
62.103 mm (2.4405 in.) mm (0.660 in.)
(2.4450 in.)

2. Using a camshaft bushing remover and installer tool ( ZTSE2893C ), select the proper size expanding collet
and back-up nut and assemble onto the expanding mandrel. With the expanding collet collapsed, install the
collet assembly into the camshaft bushing to be removed and tighten the back-up nut onto the expanding
mandrel until the collet fits the camshaft housing. Refer to Figures 5.26 and 5.27 .

3. Assemble the puller screw and extension, if necessary and install onto the expanding mandrel. Tighten the
pulling nut against the thrust bearing and pulling plate to remove the camshaft bushing ( Figure 5.27 ).

NOTE: Be sure to hold the end of the puller screw with a wrench to prevent it from turning, when
tightening the pulling nut.

4. Repeat the procedure for each bushing.

NOTE: To remove the rear bushing, install the puller screw from the rear of the crankcase. All other
bushings are removed by going through the front of the crankcase.
CRANKCASE BUSHING BORE INSPECTION

1. Visually inspect each bushing bore in the crankcase for burrs or debris that could damage new bushings
when they are installed.

2. Remove any burrs and clean bores thoroughly before installing new camshaft bushings.
CAMSHAFT GEAR AND CAMSHAFT

REMOVAL

Refer to the appropriate manual sections for removal instructions for fuel, turbocharger, cylinder head
and front cover items.

1. Remove roller tappets and roller tappet guides from their bores. Refer to Figure 5.17 .

NOTE: Mark the tappets as to location in the crankcase, so they can be returned to their original
position.

2. Refer to Figure 5.18 , for location of gears and timing marks. Rotate the engine so that timing marks on
lower and upper idler gears, crankshaft and camshaft gears are aligned.

NOTE: PRIOR TO REMOVING ANY GEAR, MOUNT A MAGNETIC BASE DIAL INDICATOR ONTO THE
ENGINE AND CHECK FOR GEAR BACKLASH AND END PLAY. REFER TO SECTION 8, "TIMING GEAR
TRAIN AND FRONT COVER" FOR INSTRUCTION.

Figure 5.17 Removing Roller Tappet Guides

 Figure 5.18 Gears And Timing Marks
1. 1. Camshaft Gear
2. 2. Upper Idler Gear
3. 3. Crankshaft Gear
4. 4. Lower Idler Gear

3. Remove the high pressure pump as outlined in Section 12, "HIGH PRESSURE LUBE OIL SYSTEM" .

4. If removing the CAMSHAFT GEAR ONLY use the following instructions:

NOTE: Do not pry on timing disk plate.

a. Remove the three (3) screws securing the timing disk plate to the camshaft gear. Remove the timing disk
plate ( Figure 5.19 ).

b. Install camshaft gear puller ZTSE4229 to camgear.

NOTE: DO NOT USE AN IMPACT WRENCH. USE OF AN IMPACT WRENCH WILL FORCE THE
CAMSHAFT TO MOVE REARWARD, RESULTING IN EXCESS CAMSHAFT END PLAY.

c. Turn the camshaft gear puller. When the camgear has moved out approximately 13 mm (1/2 in.), use a
pry bar or ratchet to force the camshaft gear to its forward most position. Finish removing camshaft gear
 ( Figure 5.20 ).

Figure 5.19 Removing Timing Disk Plate

1. 1. Camshaft Gear
2. 2. Timing Disk Plate Mounting Bolts
3. 3. Timing Disk Plate
 Figure 5.20 Moving Camshaft Gear To Forward Position

5. IF REMOVING THE CAMSHAFT GEAR AND CAMSHAFT AS IN ASSEMBLY , remove two (2) camshaft
gear thrust plate bolts. Refer to Figure 5.21 .

NOTE: When the engine is mounted in a turnover stand, rotate engine so front of engine is facing up
(engine in vertical position). This position allows for easy removal of camshaft assembly.

6. Remove the camshaft from the crankcase by lifting the assembly straight up. Refer to Figure 5.22 .

NOTE: This method reduces the risk of damaging the camshaft journals and/or bushings.
Figure 5.21 Removing Camshaft Gear Thrust Plate Bolts
Figure 5.22 Removing Camshaft And Gear From Crankcase
INSTALLATION

CAMSHAFT ASSEMBLY

1. With the engine in the vertical position, lubricate the camshaft and the camshaft bushings using clean engine
oil.

NOTE: BE SURE TO AVOID NICKING OR SCRATCHING CAMSHAFT BUSHINGS WITH CAM LOBES.

2. Gently slide camshaft assembly into crankcase. Be careful not to damage camshaft bushings.

3. Install two (2) thrust plate mounting bolts and tighten to the special torque value. Refer to Figure 5.32 .

NOTE: Bolts securing timing disk to camgear SHOULD be replaced every time the timing disk is
removed.

4. Install camgear timing disk plate over two (2) dowel pins and tighten bolts to the special torque value
( Figure 5.33 ).

5. Install idler gears as described in Section 8, "TIMING GEAR TRAIN AND FRONT COVER" .

6. Check camshaft gear backlash and camshaft end play as described in Section 8, "TIMING GEAR TRAIN
AND FRONT COVER". Specifications must be met.
 TAPPETS

If roller tappets are re-usable, lubricate roller tappets and guides with clean engine oil. Install into their original
bores, unless new tappets are used ( Figure 5.34 ).

NOTE: BE SURE the tappet rollers all turn in the same direction as when removed.
PUSH RODS

Install push rods with the cup end up. Refer to Section 4, "CYLINDER HEAD AND VALVES" .

Figure 5.32 Install Camgear To Thrust Plate

Figure 5.33 Install Timing Disk Plate
Figure 5.34 Lubricating Roller Tappet Guides
MISCELLANEOUS INSTALLATION

Refer to the appropriate section of this publication for the installation procedures for the following items:

Turbocharger oil supply line

Turbocharger oil drain line

Turbocharger

Exhaust manifold

ECM and Mounting Bracket, if equipped

Wiring harness

Valve cover/intake manifold

Cylinder head
ROCKER ARM ASSEMBLY

MISCELLANEOUS REMOVAL

Refer to the appropriate section of this publication for the removal procedures for the following items:

Turbocharger oil supply line

Turbocharger oil drain line

Turbocharger

Exhaust manifold

ECM and Mounting Bracket, if equipped

Wiring harness

Valve cover/intake manifold

Cylinder head
REMOVAL

1. Remove valve lever (rocker arm) assembly as follows: (Refer to Figure 5.2 ).

a. Loosen all valve lever (rocker arm) adjusting screw nuts to loosen adjusting screw 1/2 turn.

NOTE: Loosening valve lever (rocker arm) adjusting screw 1/2 turn will avoid possible valve train damage
during installation.

b. Loosen six (6) valve lever (rocker arm) bracket bolts (long cylinder head bolts).

c. Lift valve lever (rocker arm) assembly from the cylinder head.

2. Remove six (6) long bolts and washers from valve lever (rocker arm) assembly and set aside.

NOTE: AT THIS STAGE OF DISASSEMBLY, MEASURE CAMSHAFT LOBE LIFT.

Figure 5.2 Removing Valve Lever Assembly

MEASURE CAMSHAFT LOBE LIFT

NOTE: CAMSHAFT WEAR CAN BE MEASURED WITHOUT COMPLETE ENGINE TEAR DOWN. WITH
THE VALVE LEVER (ROCKER ARM) ASSEMBLY REMOVED AND THE PUSH RODS IN PLACE,
MEASURE CAMSHAFT LOBE LIFT AS FOLLOWS:

1. Mount a magnetic base dial indicator on the cylinder head ( Figure 5.3 ).

2. Place dial indicator tip on top of push rod and rotate engine until push rod is at its lowest point of travel (base
circle). Then "zero" indicator. Refer to Figure 5.3 .

3. Rotate the engine and bring the push rod to its highest point of travel. Record the indicator reading. Refer to
Figure 5.4 .

4. Repeat this procedure for all lobes.

NOTE: INTAKE AND EXHAUST VALVE LOBE LIFT SPECIFICATIONS ARE DIFFERENT. IF WEAR IS
GREATER THAN 0.51 MM (0.020 IN.), REPLACE THE CAMSHAFT.

NOTE: If a complete engine overhaul is scheduled, camshaft lobe wear can be determined by
measuring lobes with a micrometer when the camshaft is removed (Figure 5.5 ). Refer to "Camshaft
Cleaning and Inspection" in this section for details.
Figure 5.3 Mounting Magnetic Base Dial Indicator
Figure 5.4 Recording Camshaft Lobe Reading
Figure 5.5 Measuring Cam Lobes With Micrometer
DISASSEMBLY

1. Place valve lever (rocker arm) assembly on a clean flat surface.

2. Using a snap ring tool, remove valve lever (rocker arm) retainer ring at end of shaft. (Refer to Figure 5.6 .

3. Slide the rocker arm components off shaft as shown in Figure 5.7 .
CLEANING

1. Immerse all components in a suitable solvent.

2. Remove and dry using filtered compressed air.

Figure 5.6. Removing Valve Lever Retaining Ring

 Figure 5.7 Valve Lever Assembly Components
1. 1. Retaining Ring
2. 2. Valve Lever
3. 3. Bracket
4. 4. Spring
5. 5. Bolt
6. 6. Shaft
INSPECTION

1. Visually inspect valve lever (rocker arm) shaft and rocker arm bushings for scoring or signs of excessive
wear. If visibly damaged, replace shaft and/or valve lever (rocker arm), as required.

NOTE: Valve levers have an oil spreader groove on the bushing. The oil spreader groove (0.011 in. -
0.018 in.) {0.028-0.046 mm} depth) is located opposite the oil hole and aids in oil dispersion over the
entire bushing surface. Refer to Figure 5.8 .
 Figure 5.8 Valve Lever Oil Spreader Groove
1. 1. Oil Spreader Groove
2. Measure valve lever bushings using a telescoping gauge ( OEM1022 ) and outside micrometer as shown in
Figure 5.9 . Measure bushings at two (2) locations, 90° apart. Record the readings.

3. Measure the valve lever shaft with a micrometer. If more than 0.13 mm (0.005 in.) difference is found
between the valve lever bushing I.D. and the valve lever shaft O.D., replace the valve lever and/or shaft,
whichever part is worn.

4. If valve levers are within specifications, they may be reused. Prior to assembly, assure oil hole in valve
levers and bushings is open by running a wire through the oil hole. Remove any blockage before assembly.
Refer to Figure 5.10 .

Figure 5.9 Measure Valve Lever Bushing

 Figure 5.10 Checking Valve Lever Oil Opening

5. Inspect all orifices for blockage. Run a wire through each to assure they are open. Refer to Figure 5.11 .

6. Inspect valve lever (rocker arm) shaft springs as follows:

a. Visually inspect for rust, pitting and cracks. Replace as required.

b. Measure the spring tension using spring tester ( ZTSE2241 ). Refer to Figure 5.12 and
"SPECIFICATIONS" .

Measure free length (no load applied).

Apply correct test load and measure test length.

c. Replace rocker arm shaft springs which do not meet "SPECIFICATIONS" .

ASSEMBLY

1. Lubricate all valve lever bushings with clean engine oil, install a retaining ring at one end of shaft and
assemble components with rocker arm shaft in the vertical position. Refer to Figure 5.13 .

Figure 5.11 Checking Valve Lever Components

Figure 5.12 Measuring Valve Lever Spring Tension

 Figure 5.13 Assembly Of Valve Lever Components

2. Arrange valve lever (rocker arm) assembly components as shown in Figure 5.14 .

NOTE: THE ROCKER ARM SHAFT IS MARKED WITH THE WORK "TOP" (Figure 5.14 ). THIS SHOULD
FACE UP AT ALL TIMES.
 Figure 5.14 Valve Lever Component Arrangement
1. 1. Retaining Ring
2. 2. Valve Lever
3. 3. Bracket
4. 4. Spring
5. 5. Shaft
6. 6. Cup Plug

NOTE: The brackets must line up over the shaft bolt grooves. Figure 5.15 shows an end view position
of the valve lever (rocker arm) shaft to the mounting bracket.

3. When all components of the valve lever (rocker arm) shaft have been installed in the correct order, attach a
retaining ring to secure the component to the shaft. Refer to Figure 5.16 .

NOTE: Cup plugs (at each end of the shaft) are replaceable. Refer to Figure 5.14 . DO NOT disturb
unless damaged, leaking hard part failure or contaminated oil. If replacement is required, pry damaged
plug out and press in a new cup plug.
 Figure 5.15 Valve Lever Bracket Assembly
1. 1. Cylinder Head
2. 2. Bracket
3. 3. Rocker Arm Shaft Position
4. 4. Mounting Bolt
5. 5. Shaft Hole
Figure 5.16 Valve Lever Shaft Cup Ends
INSTALLATION

1. Install the valve lever assembly and adjust the valve lash as outlined in Section 4, "CYLINDER HEAD AND
VALVES" .

2. Reinstall the valve cover/intake manifold and crankcase breather tube. Refer to Section 3, "MANIFOLDS"
for further information.
SECTION 5: ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY, TAPPETS AND
PUSH RODS

See new specifications at end of manual called "Specifications, Special Torque Values, and Service Tools".

EXPLODED VIEWS

EXPLODED VIEW OF ROCKER ARM ASSEMBLY, CAMSHAFT ASSEMBLY, TAPPETS AND PUSH RODS

Figure 5.1 Exploded View of Rocker Arm Assembly, Camshaft

Assembly, Tappets and Push Rods
1. 1. Screw
2. 2. Timing Sensor Disk
3. 3. Dowel Pin
4. 4. Camshaft Gear
5. 5. Bolt
6. 6. Camshaft Thrust Plate
7. 7. Woodruff Key
8. 8. Push Rod
9. 9. Valve Roller Tappet
10. 10. Roller Tappet Guide
11. 11. Camshaft Assembly
12. 12. Retainer Ring
13. 13. Valve Adjusting Screw
14. 14. Valve Lever (Rocker Arm)
15. 15. Rocker Shaft Bracket
16. 16. Rocker Arm Shaft Spring
17. 17. Rocker Arm Shaft Plug
18. 18. Rocker Arm Shaft
TAPPET INSPECTION

Visually inspect all roller tappets and rollers for pitting, roughness and free rotation of roller. Check
dimensionally, if specifications are exceeded replace the tappet.