Intake Camshaft and Valve Lifter Replacement

Intake Camshaft and Valve Lifter Replacement

Removal Procedure

1. Remove the intake camshaft position actuator. Refer Camshaft Position Intake Actuator Replacement Camshaft Position Intake Actuator Replacement.




2. Remove the intake camshaft position actuator solenoid valve bolt (1) and valve (2).




3. Remove the rear cylinder head cover plate (1).

4. Remove the fuel pump. Refer to Fuel Pump Replacement Fuel Pump Replacement.




5. Remove the intake camshaft bearing rear cap bolts and cap (2).

Note: Remove each bolt on each cap one turn at a time until there is no spring tension pushing on the camshaft.

6. Mark camshaft caps to ensure they are installed in the same position.

7. Remove the intake camshaft cap bolts.

8. Remove the camshaft caps (1).

9. Remove the intake camshaft (3).





Note: Keep all of the roller finger followers and hydraulic lash adjusters in order so that they can be reinstalled in their respective locations.

10. Remove the intake camshaft roller finger followers.




11. Remove the hydraulic lash adjusters.

Installation Procedure




1. Install the hydraulic lash adjusters into their bores in the cylinder head.

2. Lubricate the hydraulic lash adjusters. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.




3. Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.





Note: Used roller followers must be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced.

4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.





Note: If equipped with the following engine; LE5, LE9, LAT, LNF, LDK, LHU, LTD, LBN, or 2010 LAF, ensure the intake camshaft notch is in the 5 o'clock position and the exhaust camshaft notch is in the 7 o'clock position.

5. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center ( TDC), crankshaft key at 12 o'clock.





Note: If equipped with following engine; LAP, LE8, LEA, LUK, or 2011 LAF and beyond ensure the intake camshaft notch is in the 10 o'clock position and the exhaust camshaft notch is in the 7 o'clock position.

6. Ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.




7. Set the intake camshaft on top of the roller followers in the camshaft bearing journals and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.




8. Rotate the oil seal in the groove of the number one camshaft journal so the split line (1) is at approximately the 12:00 position before installing the camshaft caps.





Note: The number 1 cylinder must be at top dead center (TDC), crankshaft keyway at the 12 o'clock position.

9. Install the intake camshaft with the notch on the front at approximately the 10 o'clock position (2).

10. Install the camshaft caps and hand start the camshaft cap bolts.

11. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten the camshaft caps to 10 Nm (89 lb in).





Note: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush.

* Ensure that all sealing material has been removed from the components, and the sealing surfaces are clean and free of contamination prior to applying the sealer.

* Install and align the rear cap within 20 minutes of applying the sealer.

Note: Apply the sealer to all locations centrally locating the bead on the rail.

* Run bead to 5.0 mm, dimension a, as shown.

* Where the cap ends on the perimeter rail, extend bead approximately 4.0 mm beyond edge of cap.

* Run bead, dimension c, 32 mm from the edge of the cylinder head as shown.

* Run beads, dimension b, 20 mm from edge of cylinder head as shown.

12. Apply a 2.5 mm bead of sealer to the cylinder head at the number 6 intake camshaft rear cap mating surface. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers.

13. Install the number 6 intake camshaft rear cap.

1. Tighten the cap bolts evenly to 5 Nm (44 lb in).

2. Tighten the cap bolts evenly to 10 Nm (89 lb in).

3. Back the cap bolts out 120 degrees.

4. Tighten the cap bolts evenly a final pass to 10 Nm (89 lb in).




14. Remove all excess sealing material from the fuel pump roller lifter bore (1), and ensure the bore is free of debris. Do not allow any excess sealing material to remain within the cylinder head or on any sealing surface.

15. Remove all excess sealing material from the fuel pump assembly sealing surface (2).

16. Install the fuel pump. Refer to Fuel Pump Replacement Fuel Pump Replacement.




17. Verify the seal on the cylinder head cover plate (1) is intact and in good condition.

18. Ensure that the opening plate sealing surface is clean and free of excess sealing material. Install the rear cylinder head opening plate (1) and tighten the bolts to 10 Nm (89 lb in).




19. Install the intake camshaft position actuator solenoid valve (2). Tighten the solenoid valve bolt (1) to 10 Nm (89 lb in).

20. Install the intake camshaft position actuator. Refer Camshaft Position Intake Actuator Replacement Camshaft Position Intake Actuator Replacement.