• Remove the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Remove the vibration damper. Refer to Procedure 001-052 in Section 1.
• Remove the crankshaft pulley. Refer to Procedure 001-022 in Section 1.
• Remove the front crankshaft seal. Refer to Procedure 001-023 in Section 1.
• Remove the accessory drive seal. Refer to Procedure 001-003 in Section 1
• Remove the gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the cam follower assemblies. Refer to Procedure 004-001 in Section 4.

Install four camshaft pilots, Part Number 3824285, over the outer base circle of the valve lobes between the camshaft journals.

Use a rubber band to hold the installation pilots in place. The rubber band must straddle the valve lobe.

Use one hand to slowly rotate and pull the camshaft from the cylinder block and the other hand to balance the camshaft as it is removed.

Remove the camshaft thrust washer from the camshaft.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the camshaft with solvent.

Dry with compressed air.

NOTE: After the camshaft has been steam cleaned, do not touch the machined surfaces with bare hands. This will cause rust to form. Lubricate the camshaft with clean 15W-40 oil before handling.

Use a feeler gauge to measure the clearance between the gear and the shoulder on the camshaft.

NOTE: The clearance must not exceed 0.13 mm [0.005 in].

Measure the seven camshaft bushing journals.

Camshaft Bushing Journal Outside Diameter

Replace the camshaft if the journal dimensions do not meet specifications.

Inspect the camshaft lobes for cracks, scratches, or other damage.

Measure the camshaft thrust washer.

Camshaft Thrust Washer Thickness

Replace the thrust washer if it does not meet specifications.

Measure the camshaft bushings in the cylinder block. Refer to Procedure 001-010 in Section 1.

NOTE: The oil grooves on the thrust washer must be toward the camshaft gear to prevent thrust washer malfunction.

Apply a film of Lubriplate® 105, or equivalent, to both sides of the camshaft thrust washer.

Install the thrust washer onto the camshaft.

Install four camshaft pilots, Part Number 3375268, over the outer base circle of the valve lobes between the camshaft journals.

Use a rubber band to hold the installation pilots in place. The rubber band must straddle the valve lobes.

Apply a film of Lubriplate® 105, or equivalent, to the camshaft journals and the camshaft bushings.

Rotate the camshaft slowly as it is being installed into the cylinder block.

Align the "O" mark on the camshaft gear with the "O" mark on the crankshaft gear.

Align the timing marks on the camshaft gear with the timing marks on the accessory drive gear.

After aligning the "O" marks, push the camshaft into the bore until the thrust washer fits against the cylinder block.

Remove the camshaft installation pilots. Do not allow the rubber bands to fall into the camshaft cavity of the cylinder block when removing the installation pilots.

Use a dial indicator to check the backlash between the camshaft gear and the crankshaft gear.

Place the tip of the dial indicator against a tooth on the camshaft gear.

Turn the camshaft gear by hand as far as it will freely move, and set the dial indicator at "0" (zero).

Turn the camshaft gear by hand in the opposite direction as far as it will freely move, and read the dial indicator.

Backlash Between the Camshaft and Crankshaft Gears

If the backlash is excessive, inspect the camshaft and crankshaft gears for tooth wear and replace if necessary. If the backlash is tight, inspect for debris or damage to the gear teeth and check again.

• Install the cam follower assemblies. Refer to Procedure 004-001 in Section 4.
• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the accessory drive seal. Refer to Procedure 001-003 in Section 1
• Install the front crankshaft seal. Refer to Procedure 001-023 in Section 1.
• Install the crankshaft pulley. Refer to Procedure 001-022 in Section 1.
• Install the vibration damper. Refer to Procedure 001-052 in Section 1.
• Install the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Operate the engine until it reaches a temperature of 82°C [180°F], and check for coolant or lubricating oil leaks.