Camshaft Housing and Assembly
Camshaft Housing and Assembly
Camshaft Housing and Assembly
1 8 03-15
SUBJECT DATE
Camshaft Housing and Assembly August 2015
Remove as follows:
NOTE: This procedure applies to vehicles with a Bumper-to-Back of Cab (BBC) measurement under 120 inches.
The camshaft housing can be removed as an assembly on vehicles with over a 120-inch BBC. Refer to section
"Removal of the Camshaft Housing Assembly" for those vehicles.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
2. Disconnect the battery power to the engine. Refer to OEM procedures.
3. Open the hood.
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time-use components and MUST be replaced any time they are loosened or removed.
NOTICE: Engine size/model year specific service kits, containing all of the necessary parts to replace the high
pressure fuel rail feed lines have been released. Refer to TS letter 12 TS-9 for the high pressure fuel line kit
numbers to repair these engines.
9. Remove and discard the high pressure fuel rail feed lines.
For the three-filter fuel system, Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - Three-Filter
System".
For the two-filter fuel system, Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter
System".
10. Remove the high pressure fuel injector lines.
For the three-filter fuel system, Refer to section "Removal of the High Pressure Fuel Injector Lines - Three-Filter
System".
For the two-filter fuel system, Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter
System".
11. Remove the Pressure Limiting Valve (PLV) banjo bolt from the fuel rail. Discard the PLV banjo bolt sealing washers.
12. Disconnect the fuel rail pressure sensor, Intake Manifold Temperature (IMT) sensor and Camshaft Position (CMP)
sensor.
13. Unclip all of the electrical wiring harness attaching points from the camshaft housing.
14. Unbolt the air compressor inlet pipe from the camshaft housing and the flywheel housing.
15. Remove the bolt and the P-clip securing the doser coolant line to the camshaft housing.
16. Remove the remaining two bolts (29) and (30), if equipped, securing the camshaft housing to the cylinder head. See
illustration below.
17. Attach a suitable lifting device to the camshaft housing and lift the camshaft housing off the cylinder head.
18. Remove and discard the camshaft housing seal.
19. Place the camshaft housing on a clean and flat surface to avoid damage.
NOTE: This procedure applies to vehicles with a Bumper-to-Back of Cab (BBC) measurement over 120 inches.
For vehicles with less than a 120-inch BBC, Refer to section "Removal of the Camshaft Housing".
Table 1.
Service Tools Used in the Procedure
Tool Number Tool Name and Engine Tool Graphic
Remove as follows:
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
2. Disconnect the batteries. Refer to OEM procedures.
3. Open the hood.
19. Rotate the engine to Top Dead Center (TDC) on cylinder No. 1. Rotate the engine using barring tool (J-46392 or
W904589046300) until the TDC dot (3) is between two teeth on the flywheel and aligns with the edge of the pointer (2)
on the flywheel housing (1).
20. Remove the Crankshaft Position (CKP) sensor from the left (driver) side of the flywheel housing. Install the flywheel
housing crankshaft TDC locating pin (W470589001500) into the CKP sensor hole to verify TDC.
21. Install the proper camshaft timing tool onto the rear of the camshaft housing to verify TDC on cylinder No. 1. Do not
remove the camshaft timing tool until instructed to do so.
22. Fully loosen the overhead lash adjusters for the intake and exhaust rocker arms.
NOTICE: Loosen the camshaft housing bolts in the correct sequence to prevent damage.
NOTE: Do not remove the camshaft mounting bolts completely from the assembly.
23. Loosen the camshaft housing mounting bolts using the following instructions. Fully loosen the center bolts from the
camshaft housing (bolts 1 through 7).
24. Fully loosen the bolts on the exhaust side, excluding bolts 14 and 16.
25. Fully loosen the bolts on the intake side, excluding bolts 15 and 17.
26. Loosen the four remaining bolts (14, 15, 16, and 17) a single turn at a time, using a crisscross pattern until fully
loosened.
27. Install four lifting eyes into the rocker cover mounting holes.
NOTICE: Ensure that no debris falls into the oil galleries on the cylinder head when the camshaft housing
assembly is removed or severe engine damage can occur.
NOTE: Because of the pressure on cylinder No. 2 and No. 3 rocker arms, the housing may be stuck on the rear
alignment dowel. If it is stuck, it can be broken free by rocking down on the front of the housing. If that does not
help, a pry bar may be needed to help break it loose from the dowel.
NOTICE: No abrasive cleaning pads should be used on the gasket sealing surface.
NOTICE: Do not rest the camshaft housing assembly on the camshaft gears or damage can occur.
31. Place the camshaft housing assembly on a suitable surface on its side.