Alan Wright

[Alanwright]

Hi all,

 

I have a 2005 Voyager 2.5 CRD,  SE PLUS, manual gearbox.   Have a problem with inlet camshaft, the thread has 'gone' for bolt that secures camshaft sprocket to camshaft, so cannot achieve required torque setting to ensure sprocket doesn't turn independently of the camshaft.  How big a job is it to replace camshaft with new one? What would I need to remove to gain access to camshaft? Would it be a straight swap? Would new camshaft set itself up with respect to valve clearances etc?   

Any advice would be much appreciated.

 

Cheers, Alan.

[RichardM]

Depending on how much you value the vehicle you could try drilling out the threaded section of the camshaft and helicoil it -WARNING  may destroy the engine if not accurately done.

otherwise;

REMOVAL
(1) Remove cylinder head cover
(2) Remove camshaft position sensor and camshaft
target magnet 

(3) Remove timing belt 
(4) Remove camshaft sprockets and timing belt rear cover 
(5) Bearing caps are identified for location.
Remove the outside bearing caps first 
(6) Loosen the camshaft bearing cap attaching fasteners 
CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider.
(7) Identify the camshafts before removing from the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.

INSTALLATION
CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts.
(1) Lubricate all camshaft bearing journals, rocker arms and camshaft lobes.
(2) Install all rocker arms in original positions, if reused.
(3) Position camshafts on cylinder head bearing journals. Install right and left camshaft bearing caps No. 2 – 5 and right No. 6. Tighten M6 fasteners to 12 N·m (105 in. lbs.) in sequence shown in (Fig. 28).
(4) Apply Mopart Gasket Maker to No. 1 and No. 6 bearing caps (Fig. 29). Install bearing caps and tighten M8 fasteners to 28 N·m (250 in. lbs.).
NOTE: Bearing end caps must be installed before seals can be installed.
(5) Install camshaft oil seals (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT OIL SEAL(S) - INSTALLATION).
(6) Install camshaft target magnet and camshaft position sensor.
(7) Install cylinder head cover (Refer to 9 -ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION).
(8) Install timing belt rear cover and camshaft sprockets (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT COVER(S) - INSTALLATION).
(9) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION).CYLINDER HEAD COVER

(From the workpoo manual - sorry images are impossible to load due to stupid size restriction imposed on the forum