o fit

Operation 6-6

1  Clean and inspect all components for wear or damage. Inspect the timing case for cracks, especially around

the channels for the engine fluids.

2  Fit a new joint (A5) to the backplate.

3  Engage the backplate dowels (A3) and push the backplate onto the engine.

4  Lightly lubricate the threads and shoulders of the setscrews for the backplate with clean engine lubricating

oil.

5  Fit and tighten the setscrews to 26 Nm (19 lbf ft) 2,6 kgf m.

6  Fit the camshaft, see Operation 6-8.

7  Fit the tappets into their original bores.

8  Fit the cylinder head, see Operation 3-9.

9  Fit the oil pressure relief valve together with its ‘O’ ring (A6).

10  Fit the idler gears, see Operation 6-4.

11  Fit a new coolant filter.

12  Fit the power steering pump, see Operation 15-2, the compressor, see Operation 15-1, and their mounting

brackets, if removed earlier.

13  Fit the high-pressure pump, see Operation 10-22.

14  Fit the timing case cover, see Operation 6-2.

15  Fill the cooling system to the correct level.

16  Fill the lubricating system to the correct level with an approved oil, see Chapter 5 in the User’s Handbook.

4

5

2

1

3

7

6

9

8

A

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Camshaft and tappets

To remove

Operation 6-7

Caution: The camshaft gear is an interference fit on the camshaft and must not be removed unless it is to be

renewed. A new gear must be heated to 206 °C (400 °F) to fit onto the camshaft.

Notes:

l   The four camshaft bushes can be renewed.

l   An engine timing plate is fitted to the camshaft gear.

1  Set number 1 cylinder to TDC on the compression stroke, see Operation 8-1.

2  Drain the engine lubricating oil.

3  Drain the cooling system.

4  Remove the timing case cover, see Operation 6-1.

5  Remove the cylinder head, see Operation 3-8.

6  Remove the tappets (A) from their bores and note their relative positions.

7  Measure the backlash of the camshaft gear (B) and compare the reading with relevant Data and dimensions

for the "Timing gears" on page 15. If the backlash is incorrect, renew the gear.

A

B

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8  Remove the cap screws (C2) that retain the timing plate (C3).

9  Remove the timing plate from its dowels (C1).

10  Remove the setscrews from the camshaft thrust plate, access to the setscrews is through the two holes in

the gear face (D).

11  Carefully remove the camshaft complete with the gear.

1

4

3

2

C

D

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To fit

Operation 6-8

1  Ensure that all components are clean and are lubricated with clean engine lubricating oil.

2  Carefully fit the camshaft. Ensure that the timing marks on the upper idler gear and the camshaft gear align.

If a new gear is fitted, measure the backlash (A).

3  Engage the timing plate dowels (B1) and push the timing plate (B3) onto the camshaft gear (B4), fit and

tighten the cap screws (B2) to 7 Nm (5 lbf ft) 0,7 kgf m.

1

4

3

2

A

B

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4  Fit the tappets (C) into their original bores.

5  Fit the cylinder head, see Operation 3-9.

6  Fit the timing case cover, see Operation 6-2.

7  Fill the cooling system to the correct level.

8  Fill the lubricating oil sump to the correct level with an approved lubricating oil, see Chapter 5 in the User’s

Handbook.

C

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To inspect

Operation 6-9

With the camshaft removed from the engine, measure the camshaft lobes at line AA and at line BB in figure

(A) and record the readings.

Measure the tappets, the thrust plate and the camshaft bushes. Compare all the readings with the relevant

Data and dimensions for the "Camshaft" on page 15. Renew damaged or worn components as necessary.

A

B

B

A

A

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Peregrine EDi and 1300 Series EDi

Camshaft bushes

To renew

Operation 6-10

Special requirements

Special tools

Description

Part number

Camshaft bush remover and replacer

21825963

The four camshaft bushes have the same internal diameter, but the external diameters are different for each

bush. Refer to the relevant Data and dimensions for the "Camshaft bushes" on page 15.

The bushes must be removed and fitted in the correct sequence, they shall be referred to in this manual as

number 1 bush, number 2 bush, number 3 bush and number 4 bush. Number 1 bush is at the front of the

engine.

The rear bush is removed toward the rear of the engine, the other three bushes are removed toward the front

of the engine.

1  Remove the camshaft, see Operation 6-7.

Note: Use Tool 21825995 to remove and to fit the bushes.

2  To remove number 4 bush (A4), pull it toward the rear of the engine.

3  To remove the other three bushes, pull them toward the front of the engine in the sequence: number 1 bush

(A1), number 2 bush (A2) then the number 3 bush (A3).

4  Clean and inspect the bush housings for damage. Ensure that all the lubricating oil holes are free of debris.

5  Lubricate the bushes and the bush housings with clean engine lubricating oil.

Caution: Ensure that the lubricating oil holes of each bush are on the same side, and aligned with the

lubricating oil holes in the crankcase.

6  Fit number 4 bush (B); put it into position from the rear of the engine and then pull it toward the front of the

engine.

4

3

2

1

A

B

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7  Fit the other three bushes (C) in the sequence: number 3 bush, number 2 bush then the number 1 bush. Put

each bush into position from the front of the engine and then pull it toward the rear of the engine.

8  Fit the camshaft, see Operation 6-8.

C

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Camshaft motion sensor (CMS)

To remove and to fit

Operation 6-11

To remove

1  Disconnect the main wiring harness connector from the camshaft motion sensor (A2).

2  Remove the sensor setscrew (A1). Rotate and pull the sensor from the timing cover.

3  Retain the shims (A4) for when the sensor is fitted.

To fit

1  Clean the surfaces, and apply a small amount of engine lubricating oil to the ‘O’ ring (A3) on the CMS sensor.

2  Fit the same shims (A4) to the sensor (A2).

3  Rotate and push the sensor into the timing cover.

4  Align the sensor and tighten the setscrew (A1).

5  Connect the wiring harness to the sensor.

4

3

2

A

1

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CMS verification of clearance

To check the air gap

1  Remove the CMS sensor, see Operation 6-11.

2  Clean the CMS mounting surface on the timing cover.

3  Using a calibrated depth gauge device, measure the distance from the CMS mounting surface to a tooth on

the timing disc and note the reading.

Note: When taking this measurement, ensure that the depth gauge device is measuring to a tooth of the timing

disc and not the window between the teeth, this applies also to steps 4, 5, and 6.

1

4  Rotate the crankshaft   /  turn clockwise and repeat step 3, note the reading.

2

1

5  Rotate the crankshaft a further   /  turn clockwise and repeat step 3, note the reading.

2

1

6  Rotate the crankshaft a further   /  turn clockwise and repeat step 3, note the reading.

2

7  Add the measurements from steps 3, 4, 5, and 6.

8  Divide the total by 4 to obtain an average reading.

9  Measure the CMS sensor length from its tip to the mounting flange surface.

10  Subtract the dimension at step 9 from the average dimension at step 8. This is the CMS ‘air gap’.

11  The desired air gap is given in the relevant Data and dimensions for the "Camshaft" on page 15.

12  Subtract step 11 from the result of step 10, this is the air gap / interference.

Note: Extra shims are available in a kit that contains four shims, two of 0,127 mm (0.005 in) thickness, and

two of 0,254 mm (0.010 in) thickness.

13  Select one or more shims to get as near as possible to the air gap measurement in step 11.

14  Fit the shims to the ‘CMS’ sensor and then fit the sensor, see Operation 6-11.

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7

Cylinder block assembly

7

General description

The cylinder block is made of cast iron and provides support for the wet cylinder liners, which are also made

of cast iron.

Four bushes are fitted to the cylinder block for the camshaft journals.

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