SAFARI

ENGINE

104

Fig. 20

Fig. 21

INSPECTION AND REPAIR OF CAMSHAFT AND

CAMSHAFT BUSHINGS

1 Carry out a visual inspection of camshaft for:

Cracks, preferably check on a magnetic crack

detector.

ii. Overheating of journals, to be judged by

colour of journal bluish/brown colour

indicates overheating.

iii. Deep scoringmarks on journals and cams.

iv. Check hardness of journals and cam lobes with

skelerograph. It should be within specified

limits.

Oil pump drive gear teeth for wear.

vi. Check condition of oil passage plug on rear face

of No. 3 camshaft journal. Replace plug, if

necessary.

2 Inspect dimensionally camshaft journals and their

runout.

3 If found beyond permissible limits grind camshaft

journals to next repair size.

4 Inspect dimensionally camshaft bushes in

crankcase.

5 If found worn beyond specified limits, remove

them from crankcase with drift, 312 589 07 39 and

sleeve, 312 589 07 39 and sleeve, 312 589 33 39

Fig. 20. Pry out expansion plug at 3rd bearing

before removal of this bush.

6 Fit new bushings with same tool.

7 Line bore camshaft bushings in accordance with

dimensions of camshaft bearing journals.

8 Fit expansion plug with special tool, Part No. 2523

5890 99 02 (Fig. 21) after coating its periphery with

sealing compound.

NOTE

Camshaft bushes are serviced in semifinished

condition. After installation in crankcase it is

absolutely necessary to line bore them to

camshaft journals sizes.

Do not grind camshaft journals beyond last repair

size.

When fitting new camshaft bushings, following

care should be taken

Bushing having axial slot in bore should be fitted

in parent bore for No. 1 journal, with slot to the

front (oil flowing from this groove lubricates

camshaft thrust washer and timing gears). Also

ensure that two oil holes in this bushing are in

line with drilled oil holes in crankcase.

ii.

No. 2, and 3 bearings are identical and are fitted

with one hole in line with that in crankcase.

iii. For manufacturing reasons, all camshaft bushings

are provided with 2 holes. However, only No. 1

bearing utilizes both holes functionally whereas

in others one hole is dummy.