Thursday, June 9, 2011

How to replace Camshaft, Bearings and Lifters 1 on Bmw 325?

Inspection



The camshafts should be inspected for wear and damage. The most common form of wear on the camshafts is flattened cam lobes. It is not uncommon to find 1 or more lobes completely worn into a circle. The camshafts should be checked for wear on the bearing surfaces. The camshaft do not use separate bearing so the bearing surfaces in the head or camshaft housing should be checked. If any damage is found, the head or camshaft housing will need to be replaced.

Inspect the camshaft and lifters/followers as described earlier in this section.

Camshaft & Followers

Inspect the camshaft(s) and followers as described earlier in this section.

Removal & Installation




NOTE
The valve lifters can be removed and installed once the camshafts are removed on all models EXCEPT the M44 and M20 engines. The M44 lifters can be removed by removing the rockers. For specific details refer to the rocker removal procedures in this section. The M20 engine does not utilize a lifter.

E 36 M44 Engines


Click image to see an enlarged view

Fig. Hydraulic lash adjuster components-M44 1.9L engines



Click image to see an enlarged view

Fig. The camshaft sprockets should be positioned as shown when the engine is at TDC on the No. 1 cylinder-M44 1.9L engines



Click image to see an enlarged view

Fig. Camshaft removal tool No. 11-3-260 used to hold the camshaft in place during camshaft journal removal-M44 1.9L engines



Click image to see an enlarged view

Fig. Bearing cap bolt locations-M44 1.9L engines



Click image to see an enlarged view

Fig. Bearing caps are marked with A1 through A5 for exhaust side and E1 through E5 for intake side-M44 1.9L engines



Click image to see an enlarged view

Fig. Hold the crankshaft in TDC position with tool No. 11-2-300 -M44 1.9L engines



Click image to see an enlarged view

Fig. Camshafts are marked with "A" for exhaust and "E" for intake-M44 1.9L engines



Click image to see an enlarged view

Fig. Chain tensioner location-M44 1.9L engines



Click image to see an enlarged view

Fig. Upper chain guide location-M44 1.9L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    The lifters can be lifted out of the cylinder head once the rockers are removed.

  2. Properly relieve the residual fuel system pressure.
    NOTE
    The rockers must be kept in exact order when removed and reinstalled.

  3. Remove or disconnect the following:
    NOTE
    The Hydraulic Valve Adjuster (HVA) can also be replaced once the rocker is removed.



    Negative battery cable
    Valve cover
    Spark plugs
    Camshaft rocker fingers

  4. Remove the front, upper timing chain cover.
  5. Rotate the engine clockwise to Top Dead Center (TDC) of the firing stroke for cylinder number 1. In this position, the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the cam sprocket should face up and the dimples on the machined surface at the rear of the camshafts should be facing up.
  6. Remove the plug for the crankshaft TDC alignment hole located in the engine block just below the starter motor.
  7. Secure the crankshaft at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel.
    CAUTION
    Do not forget to remove the crankshaft alignment tool before starting the engine.

  8. Install Tool No. 11 3 240 or its equivalent to secure the camshafts at TDC on the compression stroke for cylinder number 1.
  9. Remove the timing chain hydraulic tensioner, then remove the camshaft sprocket bolts and sprockets
  10. Remove the upper camshaft chain guide.
  11. Make note of the camshaft bearing cap locations, label if necessary and remove. The intake cam bearing caps should be stamped from the factory from the front to the rear starting with E1 through E5, and the exhaust cam bearing caps from the front to the rear starting with A1 through A5.
  12. Once the cam journals are removed, the camshafts can be lifted away from the cylinder head.
    NOTE
    The intake camshaft is labeled with the letter E, the exhaust camshaft is labeled with the letter A.




  13. Thoroughly clean and inspect all of the removed components prior to reassembly.
  14. Replace the oil jet feed fitting seal located behind the camshaft sprockets between the camshafts.
  15. Secure the crankshaft at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel.
    CAUTION
    Do not forget to remove the tool before starting the engine.

  16. Apply fresh engine oil to the camshaft journals in the cylinder head, then install the camshafts with the dimples on the machined surface at the rear of the camshafts facing up.
  17. Apply fresh engine oil to the camshaft journal and the cam cap fasteners, then install the camshaft journals in the proper order. Tighten the caps evenly in at least two steps and torque as follows:

    M6 fasteners: 88.5 inch lbs. (10 Nm)
    M7 fasteners: 10 ft. lbs. (14 Nm)
    M8fasteners: 14.7 ft. lbs. (20 Nm)

  18. Install the upper camshaft chain guide.
  19. Install Tool No. 11 3 240 or its equivalent to secure the camshafts at TDC on the compression stroke for cylinder number 1. Make sure the dimples on the machined surface at the rear of the camshafts are facing up.
  20. Install the camshaft sprockets onto the camshafts with the timing chain attached making sure the sprocket and sensor plate timing marks are facing up. Install the camshaft sprocket bolts until they lightly bottom, then back off enough such that there is no free play, but the sprockets can rotate when the cam chain is tensioned.
  21. Collapse the hydraulic chain tensioner before installing as follows:
    1. Drain the oil chamber of the tensioner.
    2. Place the tensioner in a vice using soft protective jaws or wooden paint stirrers to avoid damaging the machined surface.
    3. Compress the tensioner slowly, and carefully compress it until the snap ring is almost even with the outer housing. Repeat this compression procedure a second time.

  22. Install the tensioner and using a new sealing washer, install and tighten the access plug to 29.5 ft. lbs. (40 Nm).
  23. Tighten down the camshaft sprocket bolts to 88.5 inch lbs. (10 Nm).
  24. Remove Tool Nos. 11 2 300 and 11 3 240 or their equivalents.
  25. Apply fresh engine oil to the valve tips, valve stem and the HVA hydraulic valve adjuster, then apply an assembly lubricant to the camshaft lobes and install the rockers.
  26. Install and reseal the front cover as follows:
    1. Obtain the upper front cover-to-timing chain cover rubber replacement seal.
    2. Cut the rubber seal in the timing chain cover where it meets the cylinder head.
    3. Thoroughly clean the groove in the timing chain cover with a brake cleaner or rubbing alcohol.
    4. Apply a gasket sealant such as Drei Bond® 1209 to the lower corners of the cylinder head-to-timing cover and the upper corner of the cylinder head-to-upper timing cover-to-valve cover area.
    5. Install four long guide studs, Tool No. 11 4 110 or their equivalent into the cylinder head in place of the four upper timing cover through bolts.
    6. Coat the new timing cover seals and the groove end pockets in the timing chain cover with a gasket sealant such as Drei Bond® 1209.
    7. Apply a light, thin coat of grease to the upper portion of the seal.
    8. Use tool No. 11 2 330 or a thin rectangular section of sheet metal larger than the size of the timing cover, seal and guide studs, and apply a light coating of grease to both flat surfaces.
    9. Place the tool onto the seal on top of the timing chain cover.
    10. Install the upper timing chain cover onto the guide studs and carefully press the cover into place.
    11. Install the upper timing chain cover mounting fasteners in the unoccupied bolt holes, but only tighten until resistance is felt, making sure the cover is fully seated.
    12. Carefully slide the tool away from between the timing covers.
    13. Temporarily remove the oil jet feed seal at the front of the cylinder head.
    14. Install the valve cover without the gasket using two M6 x 1.0 mm bolts and fender washers threaded into the first two threaded holes for the valve cover in the cylinder head. Tighten the bolts evenly until the valve cover presses down the upper timing chain cover such that the upper edge of the timing cover is level with the valve cover gasket surface of the cylinder head.
    15. Tighten the installed upper timing cover fasteners, then remove the guide tool and install and tighten the remaining cover fasteners. Recheck the tightness of all the upper timing cover fasteners.


Timing cover tightening specifications:



M6: 88.5 inch lbs. (10 Nm)
M7 11 ft. lbs. (15 Nm)
M8 16.2 ft. lbs. (22 Nm)
M10 34.6 ft. lbs. (47 Nm)

  1. Remove the valve cover and install the oil jet feed seal.
    CAUTION
    Failure to install the oil jet feed seal will result in engine damage.


  1. The balance of installation is the reverse of the removal procedure noting the following.
    WARNING
    Remove the crankshaft holding tool before operating the engine.

  2. Fill the engine cooling system with the recommended mixture of coolant and bleed as necessary.
    NOTE
    It may be necessary to bleed the cooling system a second time after the engine has been started and cooled.

  3. Change the engine oil and filter assembly.
  4. Check and top off all fluid levels as necessary.
  5. Connect the negative battery cable.
  6. Start the engine and check for proper operation.
    NOTE
    A new or reinstalled timing chain tensioner is without oil. During initial start up the engine must be operated at 3500 rpm for approximately 20 seconds.


E36 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Properly relieve the residual fuel pressure.
  3. Disconnect the negative battery cable.
  4. On some models it is necessary to remove the cylinder head. If the fresh air intake shroud on the firewall is removable, removing the shroud should allow enough room to remove the camshafts. If however the body of the vehicle interferes with the camshaft removal, removing the cylinder head is necessary.


NOTE
There are several tools recommended for removing the camshafts. Without these tools there is a risk the camshaft could break during removal, or damage to a valve could occur.

  1. Remove the rear hood seal, then remove the fasteners securing the sealed plastic housing for the engine wiring harness from the passenger compartment fresh air intake shroud.
  2. Remove the fasteners securing the fresh air intake shroud to the fire wall, and remove the shroud.
  3. If equipped, remove the plastic trim covers from the top of the engine.
  4. Remove the wire connectors for the ignition coils and cylinder head sensors and remove the coils, then remove the cylinder head cover.
  5. Rotate the engine in the direction of rotation to Top Dead Center (TDC) for cylinder number one. Cylinder number one will be at TDC when the intake and exhaust camshaft peaks for cylinder number one face each other
  6. Lock the engine in the TDC position by placing the holding dowel tool No. 11 2 300 through the machined hole in the engine block, just inside of the transmission bell housing mounting tab located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  7. The camshafts are held in the TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  8. Remove the valve cover mounting studs.
  9. Remove the two hex plugs at the front of the cylinder head to access the exhaust camshaft sprocket mounting bolts, then loosen the exhaust cam sprocket bolts two turns.
  10. Press down on the secondary cam chain tensioner between the two camshaft sprockets and install tool No. 11 3 292 or equivalent through the back side of the tensioner housing to hold the tensioner down. A similar sized and suitably hardened drill bit can be substituted for tool No. 11 3 292.
  11. Remove the fasteners from the front of the cylinder head securing the hydraulic variable camshaft control (VANOS) unit to the cylinder head, and inspect to make sure any hydraulic or sensor connectors have been removed or disconnected.
  12. On engines with a spring plate installed on the intake camshaft, place tool No. 11 5 490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket clockwise to allow the helical gear of the VANOS unit to release the intake camshaft and to allow the VANOS unit to be pulled away from the front of the cylinder head.
  13. If tool No. 11 5 490 or equivalent is not available, move the camshaft sprockets to release the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the intake cam sprocket to rotate both cam sprockets clockwise, while alternately pulling on the VANOS unit to release it. This procedure may need to be repeated several times to fully release the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
  14. With the VANOS assembly removed, remove the intake and exhaust camshaft sprockets, the hydraulic cam chain tensioner, and the cam chain guide.
  15. From the side of the right front area of the engine, remove the cap nut for the cam chain tensioner for the cam chain that runs between the crankshaft and the exhaust camshaft sprocket. Use care when removing the tensioner cap nut as the cam tensioner spring applies pressure to the cap nut.
  16. Remove the exhaust cam tensioner, and then release the sprocket from the cam chain.
  17. Attach a wire tie or mechanic's wire to the cam chain and temporarily secure the chain fully extended.
  18. Remove the dowel from the engine and flywheel locking the engine in the TDC position.
  19. While holding the crankshaft to exhaust camshaft cam chain, rotate the engine 30° counterclockwise to avoid damaging the valves during camshaft removal and reinstallation.
  20. With the attached wire tie or mechanic's wire secured to the cam chain, and carefully lower the chain downward making sure there is enough exposed wire to retrieve the chain for reinstallation.
  21. Remove the spark plugs and install the upper camshaft journal holding device, tool No. 11 3 260/270/250 or equivalent. Tighten the hold-down bolts in the spark plug bores to 17 ft. lbs. (23 Nm).
  22. Apply a load to the bearing caps by rotating the eccentric shaft. This relieves the tension on the bearing cap bolts. Loosen and remove the bearing cap bolts.
  23. Slowly and carefully rotate the eccentric of the cam cap holding fixture to release the camshaft.
  24. Remove and rotate the camshaft fixture tool 180° and repeat the above procedures to remove the other camshaft.
  25. Remove the camshafts and the bearing caps. Note that the intake camshaft is marked "E" and the exhaust camshaft is marked "A". The camshaft bearing are consecutively numbered and lettered with "A" or "E" to designate intake or exhaust side.
  26. Hold the valve lash compensators in place using tool 11 3 250 or equivalent, and remove the bearing plate along with the valve plungers.

To install:

  1. Apply fresh engine oil to the camshaft journals and lobes.
  2. Place the camshaft in cam journals of the cylinder head.
  3. Place the upper camshaft journal bearing caps on the camshaft in the correct order. Note that the intake camshaft is marked "E" and the exhaust camshaft is marked "A". The camshaft bearing are consecutively numbered and lettered with "A" or "E" to designate intake or exhaust side.
  4. With the spark plugs removed install the upper camshaft journal holding device, tool No. 11 3 260/270/250 or equivalent. Tighten the hold-down bolts in the spark plug bores to 17 ft. lbs. (23 Nm).
  5. Rotate the eccentric shaft of the camshaft journal holding fixture to seat the camshaft and journals into the cylinder head.
  6. Use the holding fixture to secure the camshaft journals and camshaft into the cylinder head Install the camshaft journal bolts and torque as follows:

    M6 fasteners: 88 inch lbs. (10 Nm)
    M7 fasteners: 10 ft. lbs. (14 Nm)
    M8 fasteners: 14 ft. lbs. (19 Nm)

  7. Repeat the above procedures to install the second camshaft.
  8. Remove the camshaft journal fixture tool.
  9. Align the camshafts so that lobes of the intake and exhaust cams face each other for the No. 1 cylinder. The camshafts can be turned on the hexagon casting using a 1 1 / 16 inch or 27mm open end wrench.


WARNING
Once the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before rotating the engine.

Observe the following waiting period to allow the lifters to compress fully as follows:



Room temperature: 10 minutes
Temperatures down to 50° F (10° C): 30 minutes
Temperatures below 50° F (10° C): 75 minutes

  1. With the attached wire secured to the crankshaft cam chain, carefully raise the chain upward and apply a light tension to the chain, then while holding the chain, carefully rotate the engine clockwise to TDC on cylinder number one.
  2. Lock the engine in the TDC position by placing the holding dowel tool No. 11 2 300 through the machined hole in the engine block, just inside of the transmission bell housing mounting tab located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  3. Hold the camshafts TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  4. Position the crankshaft cam chain over the exhaust cam chain sprocket and install the sprocket on the exhaust cam such that the slotted holes are centered with the fastener bores in the camshaft.
  5. Install the hydraulic cam chain tensioner, and the cam chain guide, then the intake and exhaust camshaft sprockets along with the cam chain and remove the tool used to hold the hydraulic cam chain tensioner collapsed.
  6. Install the crankshaft cam chain tensioner assembly, spring and cap nut.
  7. Apply sealant to the upper corners of the cylinder head where the VANOS housing mounts and install a new VANOS housing gasket.
  8. Press the helical gear of the VANOS assembly toward the housing and install the VANOS assembly. To do so on engines with a spring plate installed on the intake camshaft, place tool No. 11 5 490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket counterclockwise to allow the helical gear of the VANOS unit to thread into the intake camshaft and to allow the VANOS unit to be pulled into the front of the cylinder head.
  9. If tool No. 11 5 490 or equivalent is not available, move the camshaft sprockets to install the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the exhaust cam sprocket to rotate both cam sprockets counterclockwise, while alternately pressing on the VANOS unit to install it. This procedure may need to be repeated several times to fully install the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.


NOTE
Make sure when assembling the VANOS unit is able to rest on the front of the cylinder head without being forced or without binding. If the VANOS unit does not fully seat it may be necessary to reposition the camshaft sprockets such that the slots in the camshaft sprockets allow enough movement of the sprockets for the helical gear of the VANOS assembly to be fully seated during assembly.

  1. Tighten the VANOS unit fastener and then torque the camshaft sprocket bolts of both the intake and exhaust cams to 16 ft. lbs. (22 Nm).
  2. Remove the crankshaft TDC holding dowel tool No. 11 3 240 or equivalent from the engine, and remove the camshaft TDC positioning tool No. 11 3 240 or equivalent from the valve cover mating surface at the back of the cylinder head.
  3. Slowly and carefully rotate the engine clockwise four complete revolutions bringing cylinder number one to TDC. If the engine binds for any reason stop immediately to evaluate and rectify the cause of the binding.
  4. With cylinder number one at TDC slide the camshaft TDC positioning tool No. 11 3 240 or equivalent over the ends of the cams and onto the valve cover mating surface. If the tool slides over the cams and is flush with the mating surface, the camshafts are properly timed. If the tool does not slide easily over the ends of the cams, or if the tool is not flush with the valve cover mating surface, the camshaft timing must be repeated until the tool fits squarely.
  5. The balance of the assembly is in reverse order of disassembly.
  6. Check and top off all fluid levels as necessary.
  7. Connect the negative battery cable.
  8. Once the engine is started check for any fluid leaks.

M20 Engine
  1. Remove the cylinder head.
  2. Remove the rocker shaft and rocker arms.
  3. Remove the bolts holding the camshaft retainer and slide out the camshaft. Be careful not to damage the bearing surfaces while pulling out.



Click image to see an enlarged view

Fig. Removing the camshaft retainer-M20 engine



Click image to see an enlarged view

Fig. Removing the camshaft-M20 engine

To install:

  1. Slide the camshaft carefully into to the cylinder head.
  2. Check the seals and replace if necessary.
  3. Install the camshaft retainer, rocker arms and rocker shafts.

M42 Engines


Click image to see an enlarged view

Fig. The camshaft sprocket timing marks are stamped into the sprockets



Click image to see an enlarged view

Fig. The camshaft bearing caps are stamped to designate their locations. From front to rear the intake caps are marked E1-E5 and the exhaust A1-A5



Click image to see an enlarged view

Fig. Position the camshafts at TDC, compression for cylinder No. 1, then install the camshaft sprockets with the timing marks facing up



Click image to see an enlarged view

Fig. The camshafts are at TDC on the compression stroke for cylinder no. 1 when the dimples are facing up and the machined surface parallel with the cylinder head



Click image to see an enlarged view

Fig. The oil jet feed fitting seal should be replaced during reassembly



Click image to see an enlarged view

Fig. A view of an installed camshaft lifter



Click image to see an enlarged view

Fig. The camshafts are held at TDC by installing Tool No. 11 3 240 or its equivalent onto the rear of the cylinder head



Click image to see an enlarged view

Fig. The crankshaft Top Dead Center (TDC) alignment hole is on the lower left side of the engine block just below the starter motor



Click image to see an enlarged view

Fig. The crankshaft is held at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel



Click image to see an enlarged view

Fig. If the flywheel has been replaced with a competition component, the alignment hole may be absent. Use a suitable dial indicator and a long extension through the No. 1 spark plug hole to locate Top Dead Center (TDC)



Click image to see an enlarged view

Fig. The camshafts can be held and rotated using an open end wrench installed on the hex cast into the camshaft



Click image to see an enlarged view

Fig. When the camshafts are positioned at Top Dead Center (TDC) for cylinder No. 1 the camshaft alignment tool is installed-all E36 engines



Click image to see an enlarged view

Fig. The necessary camshaft and engine TDC positioning tools are readily available from companies such as Baum Tools in Sarasota, FL



Click image to see an enlarged view

Fig. Camshaft removal Tool Nos. 11 3 260 and 11 3 270 or equivalents, used to support the camshaft journals during camshaft removal-M42 and E36 6-cylinder engines



Click image to see an enlarged view

Fig. Bearing cap ID markings. The intake camshaft journals are indicated by the letter E, the exhaust journals are indicated by the letter A-M42 and E36 6-cylinder engines



Click image to see an enlarged view

Fig. Check the bore surfaces of the valve clearance compensators for scoring-M42 and E36 6-cylinder engines



Click image to see an enlarged view

Fig. The lower camshaft journal and tappet bore housings are marked A for exhaust and E for intake-M42 and E36 6-cylinder engines

  1. Properly relieve the residual fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Drain the coolant from the radiator and the engine block.
  4. Remove the valve cover as outlined in this section.
  5. Remove the spark plugs as outlined in Section 1 and cover the unused exposed holes.
  6. Rotate the engine in the direction of rotation to Top Dead Center (TDC) for cylinder number one. Cylinder number one will be at TDC when the intake and exhaust camshaft peaks for cylinder number one face each other
  7. Remove the front, upper timing chain cover.
  8. Loosen but do not remove the camshaft sprocket bolts.
  9. Remove the timing chain hydraulic tensioner, then remove the camshaft sprocket bolts and sprockets
  10. Remove the upper camshaft chain guide.
  11. Make note of the camshaft bearing cap locations, label if necessary and remove. The intake cam bearing caps should be stamped from the factory from the front to the rear starting with E1 through E5, and the exhaust cam bearing caps from the front to the rear starting with A1 through A5.
  12. Install the camshaft journal holding device, tool No. 11 3 260/270/250 or equivalent. Tighten the hold-down bolts in the spark plug bores to 17 ft. lbs. (23 Nm).
  13. Apply a load to the bearing caps by rotating the eccentric shaft. This relieves the tension on the bearing cap bolts. Loosen and remove the bearing cap bolts.
  14. Slowly and carefully rotate the eccentric of the cam cap holding fixture to release the camshaft.
  15. Remove and rotate the camshaft fixture tool 180° and repeat the above procedures to remove the other camshaft.
  16. Remove the camshafts and the bearing caps. Note that the intake camshaft is marked "E" and the exhaust camshaft is marked "A". The camshaft bearing are consecutively numbered and lettered with "A" or "E" to designate intake or exhaust side.
  17. Once the cam journals are removed, the camshafts can be lifted away from the cylinder head.


NOTE
The intake camshaft is labeled with the letter E, the exhaust camshaft is labeled with the letter A.

To install:

  1. Apply fresh engine oil to the camshaft journals and lobes.
  2. Place the camshaft in the cam journals of the cylinder head with the lobes for cylinder no. 1 facing one another.
  3. Place the upper camshaft journal bearing caps on the camshaft in the correct order. Note that the intake camshaft is marked "E" and the exhaust camshaft is marked "A". The camshaft bearing are consecutively numbered and lettered with "A" or "E" to designate intake or exhaust side.
  4. With the spark plugs removed install the upper camshaft journal holding device, tool No. 11 3 260/270/250 or equivalent. Tighten the hold-down bolts in the spark plug bores to 17 ft. lbs. (23 Nm).
  5. Rotate the eccentric shaft of the camshaft journal holding fixture to seat the camshaft and journals into the cylinder head.
  6. Use the holding fixture to secure the camshaft journals and camshaft into the cylinder head Install the camshaft journal bolts and torque as follows:

    M6 fasteners: 88 inch lbs. (10 Nm)
    M7 fasteners: 10 ft. lbs. (14 Nm)
    M8 fasteners: 14 ft. lbs. (19 Nm)

  7. Repeat the above procedures to install the second camshaft.
  8. Remove the camshaft journal fixture tool.
  9. Align the camshafts so that lobes of the intake and exhaust cams face each other for the No. 1 cylinder. The camshafts can be turned on the hexagon casting using a 1 1 / 16 inch or 27mm open end wrench.


WARNING
Once the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before rotating the engine.

Observe the following waiting period to allow the lifters to compress fully as follows:



Room temperature: 10 minutes
Temperatures down to 50° F (10° C): 30 minutes
Temperatures below 50° F (10° C): 75 minutes

  1. Install the upper camshaft chain guide.
  2. Secure the crankshaft at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel.


WARNING
Do not forget to remove the tool before starting the engine.

  1. Install Tool No. 11 3 240 or its equivalent to secure the camshafts at TDC on the compression stroke for cylinder number 1. Make sure the dimples on the machined surface at the rear of the camshafts are facing up.
  2. Install the camshaft sprockets onto the camshafts with the timing chain attached making sure the sprocket and sensor plate timing marks are facing up. Install the camshaft sprocket bolts until they lightly bottom, then back off enough such that there is no free play, but the sprockets can rotate when the cam chain is tensioned.
  3. Collapse the hydraulic chain tensioner before installing as follows:
    1. Drain the oil chamber of the tensioner.
    2. Place the tensioner in a vice using soft protective jaws or wooden paint stirrers to avoid damaging the machined surface.
    3. Compress the tensioner slowly, and carefully compress it until the snapring is almost even with the outer housing. Repeat this compression procedure a second time.

  4. Install the tensioner and using a new sealing washer, install and tighten the access plug to 29.5 ft. lbs. (40 Nm).
  5. Tighten down the camshaft sprocket bolts to 88.5 inch lbs. (10 Nm).
  6. Remove Tool Nos. 11 2 300 and 11 3 240 or their equivalents.
  7. Install and reseal the front cover as follows:
    1. Obtain the upper front cover-to-timing chain cover rubber replacement seal.
    2. Cut the rubber seal in the timing chain cover where it meets the cylinder head.
    3. Thoroughly clean the groove in the timing chain cover with a brake cleaner or rubbing alcohol.
    4. Apply a gasket sealant such as Drei Bond® 1209 to the lower corners of the cylinder head-to-timing cover and the upper corner of the cylinder head-to-upper timing cover-to-valve cover area.
    5. Install four long guide studs, Tool No. 11 4 110 or their equivalent into the cylinder head in place of the four upper timing cover through bolts.
    6. Coat the new timing cover seals and the groove end pockets in the timing chain cover with a gasket sealant such as Drei Bond® 1209.
    7. Apply a light, thin coat of grease to the upper portion of the seal.
    8. Use tool No. 11 2 330 or a thin rectangular section of sheet metal larger than the size of the timing cover, seal and guide studs, and apply a light coating of grease to both flat surfaces.
    9. Place the tool onto the seal on top of the timing chain cover.
    10. Install the upper timing chain cover onto the guide studs and carefully press the cover into place.
    11. Install the upper timing chain cover mounting fasteners in the unoccupied bolt holes, but only tighten until resistance is felt, making sure the cover is fully seated.
    12. Carefully slide the tool away from between the timing covers.
    13. Temporarily remove the oil jet feed seal at the front of the cylinder head.
    14. Install the valve cover without the gasket using two M6 x 1.0mm bolts and fender washers threaded into the first two threaded holes for the valve cover in the cylinder head. Tighten the bolts evenly until the valve cover presses down the upper timing chain cover such that the upper edge of the timing cover is level with the valve cover gasket surface of the cylinder head.
    15. Tighten the installed upper timing cover fasteners, then remove the guide tool and install and tighten the remaining cover fasteners. Recheck the tightness of all the upper timing cover fasteners.


Timing cover tightening specifications:



M6: 88.5 inch lbs. (10 Nm)
M7 11 ft. lbs. (15 Nm)
M8 16.2 ft. lbs. (22 Nm)
M10 34.6 ft. lbs. (47 Nm)

  1. Remove the valve cover and install the oil jet feed seal.


WARNING
Failure to install the oil jet feed seal will result in engine damage.

  1. The balance of installation is the reverse of the removal procedure noting the following.


WARNING
Remove the crankshaft holding tool before operating the engine.

  1. Fill the engine cooling system with the recommended mixture of coolant and bleed as necessary.


NOTE
It may be necessary to bleed the cooling system a second time after the engine has been started and cooled.

  1. Change the engine oil and filter assembly.
  2. Check and top off all fluid levels as necessary.
  3. Connect the negative battery cable.
  4. Start the engine and check for proper operation.


NOTE
A new or reinstalled timing chain tensioner is without oil. During initial start up the engine must be operated at 3500 rpm for approximately 20 seconds.

M44 Engines
  1. Properly relieve the residual fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Drain the coolant from the radiator and the engine block.
  4. Remove the valve cover as outlined in this section.
  5. Remove the spark plugs as outlined in Section 1 and cover the exposed holes.


NOTE
The rockers must be kept in exact order when removed and reinstalled.

  1. Label and remove the camshaft rocker fingers as follows. For specific details refer to the rocker removal procedures in this section.
    1. Rotate the engine clockwise until the lobe of the camshaft for the rocker to be removed is pointing up.
    2. Insert Tool No. 11 5 130 or equivalent between the camshaft and the valve.
    3. Press the valve down and remove the rocker.



NOTE
The Hydraulic Valve Adjuster (HVA) can also be lifted from the cylinder head once the rocker is removed.

  1. Remove the front, upper timing chain cover.
  2. Rotate the engine clockwise to Top Dead Center (TDC) of the firing stroke for cylinder number 1. In this position, the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the cam sprocket should face up and the dimples on the machined surface at the rear of the camshafts should be facing up.
  3. Remove the plug for the crankshaft TDC alignment hole located in the engine block just below the starter motor.
  4. Secure the crankshaft at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel.


WARNING
Do not forget to remove the crankshaft alignment tool before starting the engine!

  1. Install Tool No. 11 3 240 or its equivalent to secure the camshafts at TDC on the compression stroke for cylinder number 1.
  2. Remove the timing chain hydraulic tensioner, then remove the camshaft sprocket bolts and sprockets
  3. Remove the upper camshaft chain guide.
  4. Make note of the camshaft bearing cap locations, label if necessary and remove. The intake cam bearing caps should be stamped from the factory from the front to the rear starting with E1 through E5, and the exhaust cam bearing caps from the front to the rear starting with A1 through A5.
  5. Once the cam journals are removed, the camshafts can be lifted away from the cylinder head.


NOTE
The intake camshaft is labeled with the letter E, the exhaust camshaft is labeled with the letter A.

To install:

  1. Thoroughly clean and inspect all of the removed components prior to reassembly.
  2. Replace the oil jet feed fitting seal located behind the camshaft sprockets between the camshafts.
  3. Secure the crankshaft at TDC by inserting Tool No. 11 2 300 or its equivalent through the engine block and into the flywheel.


WARNING
Do not forget to remove the tool before starting the engine.

  1. Apply fresh engine oil to the camshaft journals in the cylinder head, then install the camshafts with the dimples on the machined surface at the rear of the camshafts facing up.
  2. Apply fresh engine oil to the camshaft journal and the cam cap fasteners, then install the camshaft journals in the proper order. Tighten the caps evenly in at least two steps and torque as follows:

    M6 fasteners: 88.5 inch lbs. (10 Nm)
    M7 fasteners: 10 ft. lbs. (14 Nm)
    M8fasteners: 14.7 ft. lbs. (20 Nm)

  3. Install the upper camshaft chain guide.
  4. Install Tool No. 11 3 240 or its equivalent to secure the camshafts at TDC on the compression stroke for cylinder number 1. Make sure the dimples on the machined surface at the rear of the camshafts are facing up.
  5. Install the camshaft sprockets onto the camshafts with the timing chain attached making sure the sprocket and sensor plate timing marks are facing up. Install the camshaft sprocket bolts until they lightly bottom, then back off enough such that there is no free play, but the sprockets can rotate when the cam chain is tensioned.
  6. Collapse the hydraulic chain tensioner before installing as follows:
    1. Drain the oil chamber of the tensioner.
    2. Place the tensioner in a vice using soft protective jaws or wooden paint stirrers to avoid damaging the machined surface.
    3. Compress the tensioner slowly, and carefully compress it until the snapring is almost even with the outer housing. Repeat this compression procedure a second time.

  7. Install the tensioner and using a new sealing washer, install and tighten the access plug to 29.5 ft. lbs. (40 Nm).
  8. Tighten down the camshaft sprocket bolts to 88.5 inch lbs. (10 Nm).
  9. Remove Tool Nos. 11 2 300 and 11 3 240 or their equivalents.
  10. Apply fresh engine oil to the valve tips, valve stem and the HVA hydraulic valve adjuster, then apply an assembly lubricant to the camshaft lobes and install the rockers.
  11. Install and reseal the front cover as follows:
    1. Obtain the upper front cover-to-timing chain cover rubber replacement seal.
    2. Cut the rubber seal in the timing chain cover where it meets the cylinder head.
    3. Thoroughly clean the groove in the timing chain cover with a brake cleaner or rubbing alcohol.
    4. Apply a gasket sealant such as Drei Bond® 1209 to the lower corners of the cylinder head-to-timing cover and the upper corner of the cylinder head-to-upper timing cover-to-valve cover area.
    5. Install four long guide studs, Tool No. 11 4 110 or their equivalent into the cylinder head in place of the four upper timing cover through bolts.
    6. Coat the new timing cover seals and the groove end pockets in the timing chain cover with a gasket sealant such as Drei Bond® 1209.
    7. Apply a light, thin coat of grease to the upper portion of the seal.
    8. Use tool No. 11 2 330 or a thin rectangular section of sheet metal larger than the size of the timing cover, seal and guide studs, and apply a light coating of grease to both flat surfaces.
    9. Place the tool onto the seal on top of the timing chain cover.
    10. Install the upper timing chain cover onto the guide studs and carefully press the cover into place.
    11. Install the upper timing chain cover mounting fasteners in the unoccupied bolt holes, but only tighten until resistance is felt, making sure the cover is fully seated.
    12. Carefully slide the tool away from between the timing covers.
    13. Temporarily remove the oil jet feed seal at the front of the cylinder head.
    14. Install the valve cover without the gasket using two M6 x 1.0mm bolts and fender washers threaded into the first two threaded holes for the valve cover in the cylinder head. Tighten the bolts evenly until the valve cover presses down the upper timing chain cover such that the upper edge of the timing cover is level with the valve cover gasket surface of the cylinder head.
    15. Tighten the installed upper timing cover fasteners, then remove the guide tool and install and tighten the remaining cover fasteners. Recheck the tightness of all the upper timing cover fasteners.


Timing cover tightening specifications:



M6: 88.5 inch lbs. (10 Nm)
M7 11 ft. lbs. (15 Nm)
M8 16.2 ft. lbs. (22 Nm)
M10 34.6 ft. lbs. (47 Nm)

  1. Remove the valve cover and install the oil jet feed seal.


WARNING
Failure to install the oil jet feed seal will result in engine damage.

  1. The balance of installation is the reverse of the removal procedure noting the following.


WARNING
Remove the crankshaft holding tool before operating the engine.

  1. Fill the engine cooling system with the recommended mixture of coolant and bleed as necessary.


NOTE
It may be necessary to bleed the cooling system a second time after the engine has been started and cooled.

  1. Change the engine oil and filter assembly.
  2. Check and top off all fluid levels as necessary.
  3. Connect the negative battery cable.
  4. Start the engine and check for proper operation.


NOTE
A new or reinstalled timing chain tensioner is without oil. During initial start up the engine must be operated at 3500 rpm for approximately 20 seconds.


To Order car parts online:--To get heavy discount on car parts .Click this link below:----

http://technoanswers.blogspot.com/2011/05/from-where-to-order-car-parts-online.html

For car error code diagnosis click the link below:---

http://www.automd.com/diagnose/?amdcid=apwldrbrd1

Car no start:--

http://technoanswers.blogspot.com/2011/05/car-will-turn-over-but-will-not-start.html

1 comment:

  1. Nice blog. I had fun reading this. And it is easy to understand. Nice going. hydrodynamic bearings


    ReplyDelete