Replace Camshaft, Bearings & Lifters on Dodge Sprinter?

In this chapter details are provided for Dodge Sprinter Van/ Truck models.

The details for
How to replace Camshaft on Dodge Sprinter.
How to replace Camshaft bearings and Lifters on Sprinter.
The Procedure for 2.7L Engine, 3.0L Engine and 3.5L Engine.
How To Inspect Camshaft Lifter Assembly.

All this Procedure details are provided here.

The details are as follows:---


Bearing Replacement:--
WARNING
Replacement of the camshaft will also require replacement of the finger followers and hydraulic lifters.

Inspection:--
Clean each lifter assembly in cleaning solvent to remove all varnish and sludge deposits. Inspect for indications of scuffing on the side and base of each lifter body.
Squeeze the lifter and be sure that the spring returns the lifter to its correct position.
Inspect the retaining clip and rocker arm roller for damage or excessive wear.
Replace any worn or damaged components.

Removal & Installation

2.7L Engine

1. Disconnect the negative battery cable.
2. Remove the engine appearance cover.
3. Remove the high pressure lines and fuel injectors. For additional information, refer to the following section, "Fuel Injectors, Removal & Installation.-
4. Remove the air intake assembly.
5. Detach the hose from the oil separator.
6. Disconnect the camshaft position sensor.
7. Remove the cylinder head cover.
8. Rotate the crankshaft clockwise to put cylinder no. 1 at Top Dead Center (TDC).
9. Lock the intake camshaft.
10. Remove the timing chain tensioner. For additional information, refer to the following section, "Timing Chain, Sprockets, Front Cover & Seal, Removal & Installation.-
11. Remove the vacuum pump.
12. Remove the cylinder head front cover bolts.
13. Raise the locking pawl of the top guide rail and remove the cylinder head front cover.
14. Counter hold the camshaft with an open end wrench and unbolt the driver of the intake camshaft sprocket.
15. Remove the top guide rail.
16. Matchmark the camshaft sprocket relative to the timing chain.
17. Unbolt the camshaft sprocket from the exhaust camshaft.
18. Remove the camshaft sprocket.
19. Matchmark each camshaft bearing cap, identifying its position.
    
    WARNING

    Slacken the bolts of the camshaft bearing caps evenly in steps of one turn until the back pressure is eliminated. Camshafts must not be twisted when slackening the camshaft bearing caps.
20. Remove the exhaust camshaft bearing caps 1, 3, 4 and 6, in sequence.
21. Remove the intake camshaft bearing caps 1, 3, 4 and 6, in sequence.
22. Slacken the exhaust camshaft bearing bolts individually at cap 2 and then 5. Remove the bolts one revolution at a time until the back pressure is released.
23. Slacken the intake camshaft bearing bolts individually at cap 2 and then 5. Remove the bolts one revolution at a time until the back pressure is released.
24. Remove the camshafts. 
    
    
    
    Fig. Remove the cylinder head cover (2), timing chain tensioner (7), vacuum pump (8), and cylinder head front cover (5) before remove the camshafts-2.7L Engine shown

To install:

1. Install intake and exhaust camshafts so that the two holes in camshaft sprockets are positioned opposite and the markings of the camshaft and camshaft bearing cap are aligned.
2. Ensure that cylinder no. 1 is set to TDC.
3. Install the Nos. 2 and 5 Exhaust cam bearing caps.
4. Install the Nos. 2 and 5 Intake cam bearing caps.
5. Tighten each of the Nos. 2 and 5 intake and exhaust bearing cap bolts evenly to 80 inch lbs. (9 Nm) in steps of 1 revolution each. 
   
   
   
   Fig. Install the Nos. 2 and 5 camshaft bearing caps first-2.7L Engine shown
6. Install the remaining camshaft bearing caps and tighten the bolts evenly to 80 inch lbs. (9 Nm) in steps of 1 revolution each. 
   
   
   

   Fig. Then install the remaining camshaft bearing caps-2.7L Engine shown.
7. Insert a locking pin through the first camshaft bearing cap into the whole in the camshaft sprocket.
8. Install the camshaft sprocket with timing chain fitted on, onto exhaust camshaft paying attention to position of dowel pin. Tighten a new bolt to 13 ft. lbs. (18 Nm).
9. Install the timing chain tensioner.
10. Ensure the two markings in the inlet camshaft sprockets must be positioned opposite and markings of camshaft and camshaft bearing cap are aligned.
11. Insert the slide rail and bolt the driver into the inlet camshaft. Tighten the bolt driver to 37 ft. lbs. (50 Nm).
12. Install the front cover on the cylinder head.
13. Install the cylinder head cover.
14. Clean and install the fuel injectors
15. Reconnect the negative battery cable.
16. Install the engine appearance cover.
17. Start the engine and check for leaks.

3.0L Engines
Left Side

1. Disconnect negative battery cable.
2. Remove engine appearance cover.
3. Rotate the engine to Top Dead Center (TDC) using the crankshaft damper bolt.
4. Remove the main engine wiring harness retainers at the rear of the cylinder head cover.
5. Remove the EGR valve.
6. Remove the charge air inlet tube.
7. Disconnect the fuel line hoses at the fuel rail, high pressure pump using Special Tool 9539 Pliers.
8. Disconnect the fuel lines at the left cylinder head.
9. Remove the fuel pipe bundle and set it aside.
10. Remove the oil filter housing support bracket.
11. Remove the cylinder head cover.
    
    NOTE

    The left exhaust camshaft gear alignment mark is located in the gear tooth valley. The left intake camshaft gear mark is located on the outside of the tooth.
12. Check the camshaft timing gears for alignment. The alignment marks should be touching and the exhaust camshaft drive gear alignment pin should be located at approximately 12 o'clock, when viewed from the front camshaft seal.
13. Rotate the engine by the vibration damper bolt, past TDC to gain access to the lower camshaft drive gear bolt, and remove the bolt.
14. Rotate the engine back to TDC and check the camshaft gear alignment.
15. Remove the timing chain tensioner.
16. Matchmark the timing chain in relation to the camshaft sprocket.
17. Tie a strap around the timing chain and secure it to the camshaft sprocket.
18. Remove the remaining camshaft drive gear bolts and separate the drive gear from camshaft gear.
19. Remove the intake and exhaust camshaft retainers.
20. Remove the left cylinder head camshafts.

To install:

1. Clean all of the mating surfaces.
2. Lubricate the camshafts with clean engine oil.
3. Carefully install the camshafts onto the cylinder head journals and align the camshaft gear timing marks.
4. Install the camshaft retainers and tighten each retaining bolt to 80 in. lbs. (9 Nm).
5. After the camshafts are properly installed in cylinder head cover check end play of camshafts with a dial indicator.
   
   NOTE

   The left exhaust camshaft gear alignment mark is located in the gear tooth valley. The left intake camshaft gear mark is located on the outside of the tooth.
   
   
   
   NOTE

   The alignment marks should be touching and the exhaust camshaft drive gear alignment pin should be located at approximately 12 o'clock, when viewed from the front camshaft seal.
6. Ensure the proper positioning of the camshaft gear alignment marks and install the camshaft driven gear onto the exhaust camshaft alignment dowel.
7. Install two of the drive gear bolts and tighten the bolts to 13 ft. lbs. (18 Nm).
8. Ensure the proper positioning of the timing chain to drive gear matchmarks and remove the tie strap.
9. Rotate the engine by the crankshaft damper bolt enough to install the third camshaft drive gear bolt. Tighten the bolt to 13 ft. lbs. (18 Nm).
10. Rotate the engine back to TDC and check camshaft gear alignment.
11. Install the timing chain tensioner.
12. Install the left front camshaft oil seal.
13. Install the left rear camshaft oil seal (2).
    
    NOTE

    Care must be taken not to get any engine sealant on the camshaft journals of the cylinder head cover.
14. Install a ¹ / ₈ inch bead of Mopar® Engine RTV Gen II sealant to the underside of the cylinder head cover.
15. Carefully position the cylinder head cover and install the bolts into their original position.
    
    WARNING

    The cylinder head cover bolts are different lengths. Do not use the wrong length bolts or engine damage may result.
16. Tighten cylinder head cover bolts in sequence, first to 35 in. lbs. (4 Nm), and then repeat the sequence to 75 inch lbs. (8.4 Nm).
17. Install the EGR valve.
    
    CAUTION

    The fuel injector sealing washers MUST be replaced. DO NOT use the old sealing washers or double the sealing washers.
    
    
    
    NOTE

    Care must be taken not to apply any lubricant to the fuel injector nozzles.
18. Install the fuel injectors. Tighten the injector retaining claw bolt to 60 inch lbs. (7 Nm) and then an additional 180°.
19. Re-position and secure the engine harness.
20. Install the left fuel rail. Tighten the fuel rail bolts to 98 inch lbs. (11 Nm).
21. Position the return fuel lines and secure to the injectors. Push down on the release lock tab to secure.
22. Connect the fuel injector electrical connectors.
23. Install the left rear engine cover bracket.
24. Install the high pressure fuel lines from the fuel rail to injectors. Tighten the line connections to 20 ft. lbs. (27 Nm).
25. Install the fuel line from the high pressure pump to the left fuel rail. Tighten the retaining bolt to 22 ft. lbs. (30 Nm).
26. Install the fuel supply line to the fuel filter and high pressure pump.
27. Connect both fuel lines at the high pressure pump.
28. Install the air filter housing and tube.
29. Connect the negative battery cable.
30. Install the engine appearance cover.
31. Start the engine and check for leaks.

Right Side

1. Disconnect the negative battery cable.
2. Remove the engine appearance cover.
3. Rotate the engine to Top Dead Center (TDC) using the crankshaft damper bolt.
4. Remove the intake air resonator.
5. Remove the vacuum pump.
6. Remove the oil level indicator tube retaining bolt at the right cylinder head cover.
7. Remove the crankcase breather assembly from the right cylinder head cover.
8. Remove the cylinder head cover.
   
   NOTE

   The right exhaust camshaft gear alignment mark is located in the gear tooth valley. The left intake camshaft gear mark is located on the outside of the tooth.
9. Check the camshaft timing gears for alignment. The alignment marks should be touching and the exhaust camshaft drive gear alignment pin should be located at approximately 12 o'clock, when viewed from the front camshaft seal.
10. Rotate the engine by the vibration damper bolt, past TDC to gain access to the lower camshaft drive gear bolt, and remove the bolt.
11. Rotate the engine back to TDC and check camshaft gear alignment.
12. Remove the timing chain tensioner.
13. Matchmark the timing chain in relation to the camshaft drive gear.
14. Tie a strap the timing chain to the drive gear.
15. Remove the remaining camshaft drive gear bolts and separate the drive gear from camshaft gear.
16. Remove the intake and exhaust camshaft retainers.
17. Remove the left cylinder head camshafts.

To install:

1. Clean all mating surfaces and lubricate camshafts with clean engine oil.
2. Carefully install camshafts onto cylinder head journals and align the camshaft gear timing marks.
3. Install the camshaft retainers and tighten each retaining bolt to 80 inch lbs. (9 Nm).
4. After camshafts are properly installed in cylinder head cover check end play of camshafts with a dial indicator.
   
   NOTE

   If the camshaft endplay is not within specification, replace the cylinder head and cylinder head cover.
   
   
   
   NOTE

   The right exhaust camshaft gear alignment mark is located in the gear tooth valley. The right intake camshaft gear mark is located on the outside of the tooth. The alignment marks should be touching and the exhaust camshaft drive gear alignment pin should be located at approximately 12 o'clock, when viewed from the front camshaft seal.
5. Ensure the proper positioning of the camshaft gear alignment marks and install the camshaft driven gear onto the exhaust camshaft alignment dowel.
6. Install two of the drive gear bolts and tighten to 13 ft. lbs. (18 Nm).
7. Ensure the proper positioning of the timing chain to drive gear matchmarks and remove the tie strap.
8. Rotate the engine by the crankshaft damper bolt enough to install the third camshaft drive gear bolt. Tighten the bolt to 13 ft. lbs. (18 Nm).
9. Rotate the engine back to TDC and check camshaft gear alignment.
   
   WARNING

   Turn the engine clockwise only!
10. Install the timing chain tensioner.
    
    NOTE

    Care must be taken not to get any engine sealer on the camshaft journals.
11. Apply a ¹ / ₈ inch bead of Mopar®® Engine RTV Sealant to the cylinder head cover.
12. Install the camshaft seal into position.
13. Install the cylinder head cover. Tighten the bolts in sequence as follows:
    1. Tighten the bolts to 35 inch lbs. (4 Nm).
    2. Tighten the bolts to 53 inch lbs. (6 Nm).
    3. Then tighten the bolts to 75 inch lbs. (8.4 Nm).
14. Install the oil separator housing adapter with a new camshaft seal and tighten fasteners to 80 inch lbs. (9 Nm).
15. Install the oil separator and tighten fasteners to 80 inch lbs. (9 Nm).
16. Secure the transmission tube fastener to the engine cover bracket.
17. Secure the heater hose bracket to the cylinder head cover.
18. Secure the vacuum pump hose pipe to the cylinder head cover.
19. Install the fuel injectors. For additional information, refer to the following section, "Fuel Injectors, Removal & Installation.-
20. Connect the camshaft position sensor and fuel injector wiring harness connectors.
21. Connect the return fuel hose to each injector.
22. Install the fuel rail, high pressure fuel lines and injector cover.
23. Secure the oil dipstick tube to the cylinder head and tighten the bolt to 98 inch lbs. (11 Nm).
24. Install the vacuum pump.
25. Install the air control valve resonator.
26. Install the air cleaner outlet tube to the turbocharger and secure the air cleaner housing cover.
27. Install the engine appearance cover.
28. Connect the negative battery cable.
29. Start the engine and check for leaks.

3.5L Engine
Left

1. Disconnect the negative battery cable.
2. Disconnect the remote ground cable by the accelerator pedal.
3. Remove the air intake assembly.
4. Remove the left cylinder head cover. For additional information, refer to the following section, "Cylinder Head, Removal & Installation.-
5. Place a drift into the camshaft adjuster to lock it into position.
6. Hold the back of the camshaft with a Torx bit while removing the center valve from the front of the camshaft.
7. Remove the pulse wheel from the camshaft.
   
   CAUTION

   Use care not to nick or scratch the journals when removing the camshaft.
8. Remove the camshaft hold downs.
9. Remove the camshafts from the camshaft adjuster.
   
   
   

   

   Fig. Remove the camshaft hold downs (1) to remove the camshafts (2,3) from the adjuster-3.5L Engine Left Camshafts

To install:

1. Install the camshafts into the camshaft adjuster.
2. Install the camshaft hold downs.
3. Install a new pulse wheel onto the camshaft adjusters.
4. Remove the drift from the camshaft adjuster.
5. Hold the back of the camshaft with a Torx bit while installing the center valve into the front of the camshaft.
6. Install the left cylinder head cover.
7. Install the air intake assembly.
8. Connect the remote ground.
9. Connect the negative battery cable.
10. Start the engine and check for leaks.

Right

1. Disconnect the negative battery cable.
2. Remove the air intake assembly.
3. Turn the engine in the direction of rotation until the engine is set to 40 degrees after Top Dead Center (TDC).
4. Remove the air control valve on the right cylinder head.
5. Remove the air control valve gasket and bracket.
6. Remove the centrifugal oil separator cover.
7. Remove the center bolt from the oil separator.
8. Remove the oil separator.
9. Remove the camshaft plug.
10. Disconnect the camshaft position sensors in the right front upper cover.
    
    
    

    

    Fig. Disconnect the camshaft position sensors (1,2) and then remove the upper front cover (3)-3.5L Engine Right Camshaft removal
11. Remove the upper front cover on the right cylinder head.
12. Remove the bolts from the engine wiring harness on the right cylinder head cover.
13. Disconnect the engine wiring harness and secure it out of the way.
14. Disconnect and remove the ignition coils.
15. Remove the cylinder head cover.
16. Install a drift into the camshaft to hold the split gears in place.
    
    
    

    

    Fig. Install a drift (3) into the camshaft to hold the split gears (1,2) in place-3.5L Engine Right Camshaft removal
17. Use a Torx bit to the end of the camshaft while removing the center valve from the camshaft adjuster in the intake camshaft.
18. Remove the intake camshaft pulse wheel.
19. Use a Torx bit to the end of the camshaft while removing the center valve from the camshaft adjuster in the exhaust camshaft.
    
    
    

    

    Fig. Use a Torx bit to the end of the camshaft while removing the center valve from the camshaft adjuster in the exhaust camshaft-3.5L Engine Right Camshaft removal
20. Remove the exhaust camshaft pulse wheel.
21. Support the timing chain to prevent the chain from slipping from the crankshaft sprocket.
22. Remove the exhaust camshaft adjuster.
23. Remove the intake camshaft adjuster.
24. Remove the camshafts.

To install:

1. Make sure that the crankshaft is set to 40 degrees after top dead center.
2. Install the camshafts.
3. Install the camshaft hold downs.
4. Install the intake camshaft adjuster.
5. Install the exhaust camshaft adjuster.
6. Remove the drift from the camshaft adjuster.
7. Make sure that when the timing chain is installed, the camshaft adjuster marks line up as illustrated.
   
   
   

   

   Fig. Make sure that when the timing chain is installed, the camshaft adjuster marks line up as illustrated-3.5L Engine Right Camshaft
8. Use a Torx bit to the end of the camshaft while installing the center valve to the camshaft adjuster in the exhaust camshaft.
9. Install the exhaust camshaft pulse wheel.
10. Use a Torx bit to the end of the camshaft while installing the center valve from the camshaft adjuster in the intake camshaft.
11. Install the intake camshaft pulse wheel.
12. Install the camshaft adjuster center bolts.
13. Install the cylinder head cover.
14. Install and connect the ignition coils.
15. Install and connect the engine wiring harness.
16. Install the upper front cover on the right cylinder head.
17. Make sure that the number stamp can be seen through the camshaft sensor holes (see illustration).
    
    
    

    

    Fig. Make sure that the number stamp can be seen through the camshaft sensor holes (3)-3.5L Engine Right Camshaft
18. Connect the camshaft position sensors in the right front upper cover.
19. Install the oil separator.
20. Install the center bolt to the oil separator.
21. Install the centrifugal oil separator cover.
22. Install the camshaft plug.
23. Install the air control valve gasket.
24. Install the air control valve on the right cylinder head.
25. Install the air control valve bracket.
26. Install the air intake assembly.
27. Connect the negative battery cable.
28. Start the engine and check for leaks.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html