Camshaft Position Exhaust Actuator Replacement

Camshaft Position Exhaust Actuator Replacement

Tools Required

* J 44217 Timing Chain Tensioner Tool
* J 45027 Tensioner Tool
* J 45059 Angle Meter

Removal Procedure




1. Remove the camshaft cover.
2. Remove the upper timing chain guide bolts and guide.




3. Remove the timing chain tensioner.
4. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
5. Loosen, but DO NOT remove the exhaust camshaft actuator bolt.





Important: Ensure that the tips of the J44217 are fully engaged into the timing chain.

6. Install one of the tools (1) from the J44217 to the exhaust camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.





Important: Ensure that the tips of the J44217 are fully engaged into the timing chain.

7. Install one of the tools (1) from the J44217 to the intake camshaft side of the timing chain assembly in order to retain the timing chain. Firmly tighten the nuts.





Important: Ensure that the timing chain and the camshaft position actuators are marked for proper assembly.

8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
9. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.
10. Remove and discard the exhaust camshaft actuator bolt (2).
11. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

Installation Procedure





Important: Ensure that the alignment mark made previously on the intake camshaft actuator is still aligned properly with the mark on the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.




4. Remove the tool (1) from the intake camshaft side of the timing chain assembly.




5. Remove the tool (1) from the exhaust camshaft side of the timing chain assembly.
6. Install a 24 mm wrench onto the hex on the camshaft in order to hold the camshaft.

Notice: Refer to Fastener Notice.

7. Tighten the NEW camshaft actuator bolt.

Tighten the bolt to 85 N.m (63 lb ft), plus an additional 30 degrees using the J45059.




8. Remove the old oil from the timing chain tensioner.
9. Inspect the timing chain tensioner for scoring or free movement.
10. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
11. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 in) from end to end (a).




12. If the timing chain tensioner is not in the compressed state, perform the following steps:
1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
2. Install the J 45027-2 (2) into a vise.
3. Install the notch end of the piston assembly into the J 45027-2 (2).
4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.




13. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
14. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
15. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1- 8.4.




16. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
17. Install the timing chain tensioner.

Tighten the tensioner to 75 N.m (66 lb ft).

18. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the timing chain, then give a sharp jolt diagonally downwards to release the tensioner.




19. Install the upper timing chain guide and bolts.

Tighten the bolts to 10 N.m (89 lb in).

20. Install the camshaft cover.