Camshaft replacement in the diesel engine is a thorny affair for there are special tools and means of Lash Adjuster retention available. Before starting, if the vehicle features air conditioning and you plan to remove the camshaft with the engine in place, a trained professional should have the air conditioning system discharged. Start by removing the crankshaft damper and gear housing cover followed by the radiator, upper radiator support panel, intercooler, and air conditioning condenser. If method two is chosen for Lash Adjuster retention it will be necessary to take away the fuel transfer pump, fuel filter/water separator, and fuel injection pump. Put the engine at TDC for cylinder number 1 then continue to remove the valve cover rocker arm push-rods. For Method One, you will use wooden dowels to hold onto your Lash Adjusters into their bores when you need them, while small hoses keep it stuck at the top of its bore if method two is selected. Insert dowels through pushrod holes and secure with rubber bands so that they keep Lash Adjusters up. You can now take out the camshaft only after all Lash Adjusters are secured. In this case, use small hose clamps to secure the Lash Adjusters at their "full-up" height in Method Two or even use wooden dowels aside from having 'O' ring retaining springs between each pair of valves in Method One since these methods allow both types of retainers to be engaged simultaneously on opposite sides of each cylinder head. Remove camshaft thrust plate bolts ensuring that it does not go too deep into the block once camshafts are properly secured in their position via clamping down by using such things like hose clamps or dowel pins where needed. After removing, inspect cam shafts and Lash Adjusters for wear & tear / damage/ measurements with relation to wear rate under these different conditions until change. A new one should replace worn-out components as need dictates. Lubricate the camshaft fully and place it into the block with timing marks aligned on the camshaft gear and crankshaft gear. Secure the camshaft thrust plate bolts, not pushing the camshaft too far down into the block. Pushrods, rocker arms, and other components can now be reassembled after removing all Lash Adjuster retaining dowels or clamps. Check valve clearance & complete the installation process including engine oil change as well as filter. Install the side cover with a new gasket if it was removed. Finally, have the air conditioning system evacuated, recharged, and leak tested by a professional shop.
