Camshaft and Bearings Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                      General Safety Instructions:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N05                                       WARNING
Rocker Stud Socket, J36003                                 To      prevent        injury,
Cam Gear Retaining Tool, J35652                            compressed air will not
Cam Gear Pilot, J35906                                     exceed 30 psi (207 kPa).
Caulking Gun, 805774
                                                           Use only with effective chip
Materials/Parts:                                           guarding     and    personal
                                                           protective        equipment,
Ring, Seal (2)            P/N 8929740                      goggles, shield, and gloves.
Oil, Lubricating          Appendix B, Item 37               Camshaft weighs 53 lb (24
Eliminator, Gasket        Appendix B, Item 18              kg). Attach suitable lifting
                                                           device prior to removal to
Plastigauge               Appendix B, Item 46              prevent possible injury to
Towel, Shop               Appendix B, Item 62              personnel.

International             Appendix B, Item 29               Adhesives, solvents, and
Compound No. 2                                             sealing compounds can burn
                                                           easily, can give off harmful
Tag, Identification       Appendix B, Item 55              vapors, and are harmful to
Solvent, Drycleaning      Appendix B, Item 54              skin and clothing. To avoid
                                                           injury or death, keep away
Personnel Required: (2)                                    from open fire and use in
                                                           well-ventilated    area.   If
References:                                                adhesive, solvent or sealing
                                                           compound gets on skin or
TM 9-2320-363-20                                           clothing, wash immediately
Equipment Condition:                                       with soap and water.

Reference                 Condition Description
TM 9-2320-363-20          Tachometer Drive
                          Removed
Page 3-183                Rocker Arm Assemblies
                          Removed

TM page 3-163

Illustration from TM 9-2320-363-34-1 (PDF page 239)

1. REMOVE THREE BOLTS (1) AND REAR CAMSHAFT COVER (2).

2. WITH DIAL INDICATOR (3), PLACE POINTER IN CONTACT WITH SIDE OF CAMSHAFT LOBE (4).

3. GRASP CAMSHAFT (5) BETWEEN CAMSHAFT CAPS AND MOVE CAMSHAFT AS FAR FORWARD AS POSSIBLE. HOLD IN THAT POSITION AND ZERO DIAL INDICATOR (3).

4. MOVE CAMSHAFT (5) TO REAR AS FAR AS POSSIBLE. READ AND RECORD TOTAL AMOUNT OF END PLAY. ALLOWABLE CAMSHAFT END PLAY IS 0.003-0.015 IN. (0.076-0.381 mm).

5. IF END PLAY is BEY O ND MAXIMUM LIMIT, REMOVE AND REPAIR OR REPLACE CAM S HAFT DRIVE GEAR ASSEMBLY.

TM page 3-164

Illustration from TM 9-2320-363-34-1 (PDF page 240)

CAUTION Use only following method to hold camshaft drive gear stationary while loosening or tightening camshaft drive gear bolt to prevent damage to equipment. **NOTE** After inserting shoe of camshaft drive gear retaining tool thru access hole of camshaft drive gear, it may be necessary to bar engine over slightly to aline bolt holes in retaining tool with bolt holes in drive gear access cover. If necessary, bar engine using accessory drive pulley retaining nut to aline access hole.

6. INSTALL CAMSHAFT DRIVE GEAR RETAINING TOOL (6) ON GEAR HOUSING (7) ENGAGING ONE ACCESS HOLE (8) IN CAMSHAFT DRIVE GEAR (9). INSTALL TWO BOLTS (10) IN RETAINING TOOL (6) AND GEAR HOUSING (7).

7. REMOVE CAMSHAFT DRIVE GEAR BOLT (11).

8. REMOVE TWO BOLTS (10) AND CAMSHAFT DRIVE GEAR RETAINING TOOL (6) FROM GEAR HOUSING (7).

TM page 3-165

Illustration from TM 9-2320-363-34-1 (PDF page 241)

CAUTION

Clean shop towel may be inserted into gear housing assembly opening to trap bolts in case they are dropped. Do not allow shop towel to drop into gear housing assembly to prevent damage to equipment.

NOTE

It may be necessary to bar engine over to aline access holes in camshaft drive gear with mounting bolts in camshaft thrust plate.

9. REMOVE TWO BOLTS (12).

TM page 3-166

Illustration from TM 9-2320-363-34-1 (PDF page 242)

NOTE Performing step 10 will move camshaft drive gear hub and thrust plate forward approximately 1/4 in. (6-7 mm) until thrust plate seal is clear of camshaft front bearing cap and cylinder head.

10. INSTALL CAMSHAFT GEAR PILOT (13) ON CAMSHAFT DRIVE GEAR ACCESS OPENING (14) AND INSTALL THREE BOLTS (15). THREAD PILOT PULLER SCREW (16) INTO END OF CAMSHAFT DRIVE GEAR HUB UNTIL PULLER SCREW (16) BOTTOMS OUT.

11. IF THERE IS DOUBT OF CAMSHAFT ACCEPTABILITY, DETERMINE EXTENT OF CAMSHAFT LOBE WEAR AS FOLLOWS: A. USING SET OF 0.0015-0.010 IN. (0.038-0.254 MM) FEELER GAGES (17) AND PIECE OF SQUARE, HARD MATERIAL (18). MEASURE FLATS ON INJECTOR RISE SIDE (19) OF CAMSHAFT LOBES (20).

TM page 3-167

Illustration from TM 9-2320-363-34-1 (PDF page 243)

B. IF FLATS MEASURE LESS THAN 0.003 IN (0.076 MM) IN DEPTH, BUT THERE ARE NO OTHER CAMSHAFT DEFECTS, CAMSHAFT IS SATISFACTORY.

12. REMOVE FOUR CAMSHAFT CAP BOLTS (21).

13. USING ROCKER STUD SOCKET, REMOVE TWO ROCKER SHAFT STUDS (22) FROM CAMSHAFT BEARING CAPS (23) NO, 1 AND NO. 7.

I CAUTION I Camshaft bearing caps are numbered and must be kept in sequence and reinstalled in original positions to prevent damage to equipment. Camshaft bearing caps cannot be interchanged or transferred to another cylinder head.

NOTE

If camshaft bearing shells are to be reused tag all parts. Shell must be kept with same camshaft bearing cap.

14. REMOVE SEVEN CAMSHAFT BEARING CAPS (23) AND SEVEN UPPER CAMSHAFT BEARING SHELLS (24) TOGETHER AS UNITS.

15. REMOVE AND DISCARD TWO SEAL RINGS (25) BETWEEN CAMSHAFT BEARING CAPS (23) NO. 1 AND NO. 7 AND CYLINDER HEAD (26).

TM page 3-168

Illustration from TM 9-2320-363-34-1 (PDF page 244)

16. REMOVE PILOT PULLER SCREW (16). CAMSHAFT GEAR PILOT (13) WILL REMAIN IN PLACE, HOLDING CAMSHAFT DRIVE GEAR (9) IN CONTACT WITH ADJUSTABLE IDLER GEAR.

WARNING Camshaft weighs 53 lb (24 kg). Attach suitable lifting device prior to removal to prevent possible injury to personnel. **CAUTION** Due to size and bulk of camshaft, care must be taken and two persons should be used to lift camshaft. Use non-metallic sling positioned inboard of camshaft bearings No. 1 and No. 7 to prevent damage to equipment.

17. USING SLINGS, SLIDE CAMSHAFT (27) TOWARD REAR TO DISENGAGE DOWEL (28) FROM CAMSHAFT DRIVE GEAR HUB (29). REMOVE CAMSHAFT (27).

TM page 3-169

Illustration from TM 9-2320-363-34-1 (PDF page 245)

CAUTION

Upper and lower bearing shells are in sets and cannot be interchanged. If either upper or lower bearing is replaced, upper and lower bearing shells must also be replaced to prevent damage to equipment.

18. REMOVE SEVEN LOWER CAMSHAFT BEARING SHELLS (30). KEEP LOWER BEARING SHELLS (30) WITH THEIR CORRESPONDING UPPER CAMSHAFT BEARING SHELLS (24) AND CAMSHAFT BEARING CAPS (23).

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in well-ventilated area, If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

1. CLEAN ALL REMOVED PARTS IN CLEAN SOLVENT.

TM page 3-170

Illustration from TM 9-2320-363-34-1 (PDF page 246)

WARNING To prevent injury, compressed air will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment, goggles, shield, and gloves.

2. MAKE SURE ALL OIL PASSAGES ARE CLEAR. DRY WITH COMPRESSED AIR.

3. USE GENERAL CLEANING METHODS TO CLEAN ALL PARTS (PAGE 2-30).

1. INSPECT CAMSHAFT LOBES AND JOURNALS FOR SCORING, PllTING, OR FLAT SPOTS. IF CAMSHAFT IS SCORED, INSPECT CAMSHAFT FOLLOWER ROLLERS.

2. IF THERE IS DOUBT OF CAMSHAFT ACCEPTABILITY, DETERMINE EXTENT OF CAMSHAFT LOBE WEAR AS FOLLOWS: A. USING SET OF O. O15-O.O1O-IN. (0.038-0.254-mm) FEELER GAGES (1) AND PIECE OF SQUARE, HARD MATERIAL (2), MEASURE FLATS ON INJECTOR RISE SIDE (3) OF CAMSHAFT LOBES (4). B. IF FLATS MEASURE LESS THAN 0.003 IN. (0.076 mm) IN DEPTH, BUT THERE ARE NO OTHER CAMSHAFT DEFECTS, CAMSHAFT IS SATISFACTORY.

NOTE If one camshaft bearing needs replacement, replace all camshaft bearing shells.

c. INSPECT CAMSHAFT BEARINGS FOR SIGNS OF EXCESSIVE WEAR, SCORING, OR PITTING. D. DETERMINE CAMSHAFT BEARING CLEARANCE:

NOTE Make sure locating tangs are correctly positioned.

(1) WITH LOWER CAMSHAFT BEARING SHELLS INSTALLED IN CYLINDER HEAD, INSTALL CAMSHAFT (5) ON SEVEN CAMSHAFT BEARINGS. (2) INSTALL SEVEN UPPER CAMSHAFT BEARING SHELLS (6) IN SEVEN CAMSHAFT BEARING CAPS (7).

TM page 3-171

Illustration from TM 9-2320-363-34-1 (PDF page 247)

(3) WIPE ANY OIL FROM CAMSHAFT BEARING SHELLS AND CAMSHAFT JOURNALS. (4) PLACE PIECE OF PLASTIGAUGE (8) FULL WIDTH OF EACH UPPER CAMSHAFT BEAR- ING SHELL (6) ABOUT 1/4 IN. (6-7 mm) OFF CENTER. (5) INSTALL CAMSHAFT BEARING CAPS (7) AND CAMSHAFT BEARING SHELLS ON COR- RECT CAMSHAFT JOURNALS AND INSTALL SEVEN CAMSHAFT CAP BOLTS (9). TIGHTEN BOLTS TO 75-86 LB-FT (101-116 N.m). (6) INSTALL TWO ROCKER SHAFT STUDS (10) IN CAMSHAFT BEARING CAPS (7) NO. 1 AND NO. 7. TIGHTEN STUDS TO 75-86 LB-FT (101-116 N.m). (7) INSTALL TWO ROCKER SHAFTS (11) ON SEVEN CAMSHAFT BEARING CAPS (7). (8) INSTALL EIGHT ROCKER SHAFT SADDLE WASHERS (12), SIX BOLTS (13), AND TWO NUTS (14). TIGHTEN BOLTS AND NUTS TO 75-86 LB-FT (101-116 N.m). (9) REMOVE TWO ROCKER SHAFT NUTS (14), SIX BOLTS (13), EIGHT SADDLE WASHERS (12), AND TWO ROCKER SHAFTS (11). (10) REMOVE TWO ROCKER SHAFT STUDS (10). (11) REMOVE SEVEN OUTBOARD CAMSHAFT CAP BOLTS (9), SEVEN CAMSHAFT CAPS (7), AND SEVEN BEARING SHELLS (6).

TM page 3-172

Illustration from TM 9-2320-363-34-1 (PDF page 248)

NOTE Flattened plastigauge will adhere to either bearing shell or camshaft journal. Maximum camshaft journal-to-bearing clearance is 0.0035-0.0065 in. (0.09-0.166 mm); maximum is 0.0075 in. (191 mm) with used parts.

(12) COMPARE WIDTH OF PLASTIGAUGE (8) AT WIDEST POINT WITH GRADUATION SCALE (15) ON PLASTIGAUGE ENVELOPE TO DETERMINE BEARING CLEARANCE.

TM page 3-173

Illustration from TM 9-2320-363-34-1 (PDF page 249)

WARNING Camshaft weighs 53 lb (24 kg). Attach suitable lifting device prior to removal to prevent possible injury to personnel.

E. REMOVE CAMSHAFT (5). F. REMOVE LOWER HALF OF BEARING SHELLS (6), NO.2 THRU NO. 6.

NOTE Make sure locating tangs are correctly positioned.

G. LUBRICATE TWO UPPER AND TWO LOWER CAMSHAFT BEARING SHELLS (6) NO. 1 AND NO. 7 WITH CLEAN ENGINE LUBRICATING OIL AND INSTALL IN TWO RESPECTIVE CAMSHAFT BEARING CAPS (7). H. INSTALL CAMSHAFT (5). I. INSTALL TWO CAMSHAFT BEARING CAPS (7) NO. 1 AND NO. 7 IN CYLINDER HEAD (16) AND INSTALL TWO CAMSHAFT CAP BOLTS (9) AND TWO ROCKER SHAFT STUDS (10) IN TWO CAMSHAFT BEARING CAPS (7) NO. 1 AND NO. 7. TIGHTEN BOLTS AND STUDS TO 75-86 LB-FT (101-116 N.m). USE ROCKER STUD SOCKET TO TIGHTEN STUDS.

NOTE If camshaft runout exceeds 0.002 in. (0.050 mm), replace camshaft.

USING DIAL INDICATOR (17), CHECK RUNOUT OF CAMSHAFT (5) AT BEARING JOURNAL NO. 4. K. REMOVE TWO CAMSHAFT BEARING CAPS (7) NO 1. AND NO. 7 FROM CYLINDER HEAD (16). L. REMOVE CAMSHAFT (5).

TM page 3-174

Illustration from TM 9-2320-363-34-1 (PDF page 250)

NOTE If new bearings are installed, replace upper and lower bearing shells as sets. Note position of oil holes and locating tangs.

1. INSTALL SEVEN LOWER BEARING SHELLS (1) IN CYLINDER HEAD AND LUBRICATE CAMSHAFT BEARING SHELLS (1) WITH CLEAN ENGINE LUBRICATING OIL.

2. INSTALL TWO UPPER CAMSHAFT BEARING SHELLS (2) IN CAMSHAFT BEARING CAPS (3) NO. 1 AND NO. 7. LUBRICATE CAMSHAFT BEARING SHELLS (2) WITH CLEAN ENGINE LUBRICATING OIL.

TM page 3-175

Illustration from TM 9-2320-363-34-1 (PDF page 251)

NOTE

If new camshaft is installed, steam clean to remove rust preventive and blow dry with compressed air. Make sure dimple in thrust plate is located at 12 o’clock position before installing camshaft dowel in camshaft drive gear hub.

3. LUBRICATE CAMSHAFT LOBES AND JOURNALS WITH CLEAN ENGINE LUBRICATING OIL.

WARNING

Camshaft weighs 53 lb (24 kg), Attach suitable lifting device prior to installation to prevent possible injury to personnel.

4. USING NON-METALLIC SLING, LOWER CAMSHAFT (4) INTO POSITION AND SLIDE FORWARD, MAKING SURE CAMSHAFT DOWEL (5) ALINES WITH MATING HOLE IN CAMSHAFT DRIVE GEAR HUB (6). THIS WILL POSITION CAMSHAFT BEARING JOURNALS IN LOWER CAMSHAFT BEARING SHELLS.

TM page 3-176

Illustration from TM 9-2320-363-34-1 (PDF page 252)

CAUTION Be careful not to get gasket eliminator on camshaft bearing shell seats and bearing surfaces. Keep time to minimum between installation of camshaft bearing caps no. 1 and no. 7 and tightening of camshaft cap bolts and nuts. Make sure two seal rings are placed on cylinder head before assembling camshaft bearing caps to cylinder head Failure to do so could result in damage to equipment. **NOTE** Make sure locating tangs are correctly positioned.

5. APPLY THIN BEAD OF GASKET ELIMINATOR TO JOINT FACE SURFACES (A, B, C, AND D) OF TWO CAMSHAFT BEARING CAPS NO. 1 AND NO. 7.

TM page 3-177

Illustration from TM 9-2320-363-34-1 (PDF page 253)

6. INSTALL TWO NEW SEAL RINGS (7) IN COUNTERBORES UNDER TWO CAMSHAFT BEARING CAPS (8) NO. 1 AND NO. 7.

7. INSTALL TWO CAMSHAFT BEARING CAPS (8), NO. 1 AND NO. 7, WITH BEARING SHELLS IN PLACE.

8. TIGHTEN TWO ROCKER SHAFT STUDS (9) AND TWO CAMSHAFT CAP BOLTS (10) ON TWO CAMSHAFT BEARING CAPS (8) NO. 1 AND NO. 7 TO 75-86 LB-FT (101-116 N.m). USE ROCKER STUD SOCKET TO TIGHTEN STUDS.

TM page 3-178

Illustration from TM 9-2320-363-34-1 (PDF page 254)

9. REMOVE THREE BOLTS (11] AND CAMSHAFT GEAR PILOT (12) FROM CAMSHAFT DRIVE GEAR ACCESS OPENING (13).

CAUTION Clean shop towel may be inserted into gear housing assembly opening to trap bolts in case they are dropped. Do not allow towel to drop into gear housing assembly to prevent damage to equipment. **NOTE** Make sure camshaft, dowel is engaged.

10. INSTALL TWO BOLTS (14), TIGHTEN BOLTS ALTERNATELY TO DRAW THRUST PLATE STRAIGHT INTO GEAR HOUSING ASSEMBLY. TIGHTEN BOLTS TO 22-28 LB-FT (30-38 N.m).

TM page 3-179

Illustration from TM 9-2320-363-34-1 (PDF page 255)

CAUTION Camshaft should be held in place while installing camshaft drive gear bolt to prevent disengaging camshaft dowel from drive gear hub.

11. COAT THREADS AND UNDERSIDE HEAD OF CAMSHAFT DRIVE GEAR BOLT (15) WITH INTERNATIONAL COMPOUND N0.2. AND INSTALL BOLT HAND-TIGHT.

NOTE

After inserting shoe of camshaft drive gear retaining tool thru access hole of camshaft drive gear, it may be necessary to bar engine over slightly to aline bolt holes in retaining tool with bolt holes in drive gear access cover.

12. INSTALL CAMSHAFT DRIVE GEAR RETAINING TOOL (16) ON GEAR HOUSING (17) ENGAGING ONE OF ACCESS HOLES (18) IN CAMSHAFT DRIVE GEAR (19). INSTALL TWO BOLTS (20) IN RETAINING TOOL AND GEAR HOUSING.

13. TIGHTEN CAMSHAFT DRIVE GEAR BOLT (15) TO 225-257 LB-FT (305-348 N.m).

14. REMOVE TWO BOLTS (20) AND CAMSHAFT DRIVE GEAR RETAINING TOOL (16).

TM page 3-180

Illustration from TM 9-2320-363-34-1 (PDF page 256)

15. USING DIAL INDICATOR (21), PLACE POINTER IN CONTACT WITH SIDE OF CAMSHAFT LOBE (22).

16. MOVE CAMSHAFT (23) AS FAR FORWARD AS POSSIBLE. HOLD IN THAT POSITION AND ZERO DIAL INDICATOR (21).

17. MOVE CAMSHAFT (23) TO REAR AS FAR AS POSSIBLE. READ AND RECORD TOTAL AMOUNT OF END PLAY. ALLOWABLE CAMSHAFT END PLAY IS 0.003-0.015 IN. (0.076-0.381 mm).

18. IF END PLAY IS BEYOND MAXIMUM LIMIT, REMOVE AND REPAIR OR REPLACE CAMSHAFT DRIVE GEAR ASSEMBLY (PAGE 12-61).

TM page 3-181

Illustration from TM 9-2320-363-34-1 (PDF page 257)

NOTE Make sure all old gasket eliminator has been removed from rear camshaft cover and camshaft bearing cap no. 7 mating surfaces. If performing step 19 in vehicle, gasket eliminator is to be applied to cover.

19. APPLY THIN BEAD OF GASKET ELIMINATOR TO CAMSHAFT BEARING CAP (8) NO. 7 MATING SURFACE AND INSTALL CAMSHAFT BEARING CAP (8) NO. 7 ON CYLINDER HEAD (24).

20. INSTALL REAR CAMSHAFT COVER (25) AND THREE BOLTS (26). TIGHTEN BOLTS TO 22-28 LB-FT (30-38 N.m).

NOTE Make sure locating tangs are correctly positioned.

21. INSTALL FIVE CAMSHAFT BEARING SHELLS (27) IN CAMSHAFT BEARING CAPS (8) NO. 2, NO. 3, NO. 5, AND NO. 6. LUBRICATE.

22. INSTALL FIVE CAMSHAFT BEARING CAPS (8) ON CORRECT SADDLES ON CYLINDER HEAD (24) AND INSTALL TWO CAMSHAFT CAP BOLTS (10) HAND-TIGHT IN CAMSHAFT BEARING CAPS NO. 3 AND NO. 5.

TM page 3-182

Illustration from TM 9-2320-363-34-1 (PDF page 258)

23. INSTALL ROCKER ARM ASSEMBLIES (PAGE 3-183).

24. TIGHTEN 12 CAMSHAFT CAP AND ROCKER ARM BOLTS AND NUTS TO 75-86 LB-FT (101-116 N.m) IN SEQUENCE SHOWN.

NOTE Follow-on Maintenance: Install tachometer drive (TM 9-2320-363-20). Install engine retarder (page 3-129).

TM page Change 1 3-183

Illustration from TM 9-2320-363-34-1 (PDF page 259)