Removal & Installation
2.1L Diesel Engine
See Figure 1
- Disconnect the negative battery cable.
- Drain the cooling system.
- Remove the valve cover and timing belt cover.
- Remove the cylinder head.
- Remove the camshaft gear using tool BVI 28-01.
- Remove the oil seal from the cylinder head by prying it out using a suitable tool.
- Remove the camshaft from the cylinder head.
- Coat the camshaft with an engine oil supplement.
- Carefully install the camshaft in the cylinder head.
- Install the oil seal in the cylinder.
- Install the camshaft gear. Hold the sprocket with tool MOT 855 while tightening to 37 ft. lbs. (50 Nm).
- Install the cylinder head.
- Install the valve cover and timing belt cover.
- Fill the cooling system.
- Connect the negative battery cable.
See Figure 2
- Disconnect the battery ground.
- Drain the cooling system.
The air conditioning system must be discharged using an approved recovery/recycling machine only. Please refer to General Information & Maintenance for more information.
- Discharge the air conditioning system, remove the radiator and air conditioning condenser.
- On carbureted engines, remove the fuel pump.
- Matchmark the distributor and engine for installation. Note the rotor position by marking it on the distributor body. Unbolt and remove the distributor and wires.
- Remove the rocker arm cover.
- Remove the rocker arm assemblies.
- Remove the pushrods.
Keep everything in order for installation. If a replacement camshaft is to be installed, replace hydraulic lifters to ensure durability of camshaft lobes and lifter bottoms.
- Using a tool J-21884, or equivalent, remove the hydraulic lifters.
- Remove the vibration damper and timing chain cover.
If the camshaft sprocket appears to have been rubbing against the cover, check the oil pressure relief holes in the rear cam journal for debris.
- Remove the timing chain and sprockets.
- Slide the camshaft from the engine. If necessary, remove front bumper and/or grille to allow removal of camshaft through front of vehicle.
- Inspect the cam lobes, bearing journals, bearings and distributor drive gear for wear. Replace if necessary.
- Lubricate all moving parts with engine oil supplement prior to installation.
- Install camshaft and tighten camshaft sprocket retaining bolts.
- Remainder of installation procedure is reverse of removal.
Run engine for at least 30 minutes at varying rpm's (between 1000-2000 rpm) to allow camshaft and lifters to break-in. Change oil and filter immediately after break-in period.
See Figure 3
- Check camshaft for straightness. Place the camshaft in two V-blocks. Install a dial indicator so that the actuating point of the indicator rests on a camshaft bearing journal. Spin the camshaft and note the runout. If run-out exceeds 0.0009 in. (0.023mm) on any bearing journal, replace the camshaft.
See Figure 4
Check the lift of each lobe in consecutive order and make a note of the reading.
- Remove valve rocker arm cover(s).
- Remove the rocker arm assemblies.
- Make sure the pushrod is in the valve lifter socket. Install a dial indicator so that the actuating point of the indicator is in the pushrod socket (or the indicator ball socket adaptor is on the end of the pushrod) and in the same plane as the push rod movement.
- Install an auxiliary starter switch Crank the engine with the ignition switch OFF . Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position, the pushrod will be in its lowest position.
- Zero the dial indicator. Continue to rotate the crankshaft slowly until the pushrod is in the fully raised position.
- Compare the total lift recorded on the dial indicator with the specification shown on the Camshaft Specification chart.
- Check the accuracy of the original indicator reading by continuing to rotate the crankshaft and noting the highest lift recorded on the dial indicator. If the lift on any lobe is below specified wear limits listed, the camshaft and the valve lifters must be replaced.
- Remove the dial indicator and auxiliary starter switch.
- Install the rocker arm assemblies. Check the valve clearance. Adjust if required (refer to procedure in this information).
- Install the rocker arm cover(s).
On engines with an aluminum or nylon camshaft sprocket, prying against the sprocket, with the valve train load on the camshaft, can break or damage the sprocket. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end-play, check the valve clearance. Adjust if required (refer to procedure in this information).
- Push the camshaft toward the rear of the engine. Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw.
- Zero the dial indicator. Position a prybar between the camshaft gear and the block. Pull the camshaft forward and release it. Compare the dial indicator reading with the specifications.
- If the end play is excessive, check the spacer for correct installation before it is removed. If the spacer is correctly installed, replace the thrust plate.
- Remove the dial indicator.
- Remove the engine following the procedures in this information and install it on an engine stand.
- Remove the camshaft, flywheel and crankshaft, following the appropriate procedures. Push the pistons to the top of the cylinder.
- Remove the camshaft rear bearing bore plug. Remove the camshaft bearings with a bearing removal tool.
- Select the proper size expanding collet and back-up nut and assemble on the mandrel. With the expanding collet collapsed, install the collet assembly in the camshaft bearing and tighten the back-up nut on the expanding mandrel until the collet fits the camshaft bearing.
- Assemble the puller screw and extension (if necessary) and install on the expanding mandrel. Wrap a cloth around the threads of the puller screw to protect the front bearing or journal. Tighten the pulling nut against the thrust bearing and pulling plate to remove the camshaft bearing. Be sure to hold a wrench on the end of the puller screw to prevent it from turning.
- To remove the front bearing, install the puller from the rear of the cylinder block.
- Position the new bearings at the bearing bores, and press them in place. Be sure to center the pulling plate and puller screw to avoid damage to the bearing. Failure to use the correct expanding collet can cause severe bearing damage. Align the oil holes in the bearings with the oil holes in the cylinder block before pressing bearings into place.
- Install the camshaft rear bearing bore plug.
- Install the camshaft, crankshaft, flywheel and related parts, following the appropriate procedures.
- Install the engine in the truck, following procedures described earlier in this information.