Page 631 of 2490

1.
Remove the two bolts which secure the chain tensioner to the
cylinder head.
2. Remove the tensioner.
29
.
Remove the chain guide.
1. Remove the bolt which secures the chain guide.
2. Note the orientation of the chain guide and remove it from the upper retaining pin.
30
.
Remove the camshafts.
1. Remove the bolts which secure the camshaft caps; loosen them evenly, in stages.
2. Remove the camshaft caps. Note their orientation and markings -
each is marked with its position (a number) and orientation (an
arrow).
3. Remove the camshafts from the engine.
31
.
Remove the tappets and shims.
1. Note the position of each tappet, for reassembly, and remove each
tappet and shim assembly - retain each shim with its original
tappet.
Mark
the inside face of each tappet in pencil or felt tipped pen, with its
original position within the cylinder head.
32
.
Remove residual coolant from the cylinder head.
1. Place a drain tray under the engine.
2. Use a syringe with a length of thin rubber pipe connected, to drain the residual coolant from the outlet pipe water-way.
A s
uitable syringe is Snap On YA 745.
33. Remove the cylinder head.
1. Place cloth around the area of th e cylinder head to absorb coolant
spillage, when removing the head.
2. Remove the bolts (10xM10 and 2xM8) which secure the cylinder
Page 665 of 2490

6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 2 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
removing the bolt which secures the sprocket.
1. Place a flat piece of stee l strip along the timing cover
horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
11. A ball-ended hexagon drive bit is required to remove the
sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.
Page 669 of 2490
6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 2 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
Page 673 of 2490

6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 1 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
removing the bolt which secures the sprocket.
1. Place a flat piece of stee l strip along the timing cover
horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
11. A ball-ended hexagon drive bit is required to remove the
sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.
Page 678 of 2490
6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 1 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
Page 811 of 2490

6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 2 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
removing the bolt which secures the sprocket.
1. Place a flat piece of stee l strip along the timing cover
horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
11. A ball-ended hexagon drive bit is required to remove the
sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.
Page 816 of 2490
6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 2 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
Page 821 of 2490

6. Rotate the crankshaft until the triangular arrow indent on
the drive plate is visible thro ugh the access hole; confirm
that the timing flat on ea ch camshaft is uppermost.
7. Install the crankshaft setting peg 303-531 to the crankshaft
position sensor location.
1. Install the crankshaft setting peg 303-531.
Position the crankshaft so that the setting peg engages
fully into the timing slot.
2. Install and tighten the bolt to secure the setting peg.
8. Lower the vehicle on the ramp.
9. Install the camshaft locking tool 303-530 to Bank 1 camshafts,
aligning the shafts sl ightly as necessary.
10. CAUTION: Use a length of steel strip that will not fall
into the timing cover.
Protect the upper face of the ti ming cover from scratches, when
removing the bolt which secures the sprocket.
1. Place a flat piece of stee l strip along the timing cover
horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
11. A ball-ended hexagon drive bit is required to remove the
sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.