1.03.053 GM 4.3 Camshaft removal and installation procedure

This Policy is completed and is waiting on Field Service, Engineering, and Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for removing and installing the engine camshaft on General Motors 4.3 Vortec style engines as laid out in this procedure.

Procedure

This procedure applies to all General Motors 4.3 Vortec style engines on Flogistix skids equipped with the General Motors 4.3 Vortec engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the torque procedure as outlined in this procedure.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

GM 4.3 Camshaft removal procedure

Remove the engine front cover bolts. Important note: After the composite engine cover is removed, Do Not reinstall the engine front cover. Always install a NEW engine front cover.

Remove the crankshaft position sensor reluctor ring (see example below)

Check the camshaft timing chain free play.

• Rotate the camshaft sprocket (1) counterclockwise until all slack is removed from the camshaft timing chain (2).

• Measure the free play on the slack side (3) of the camshaft timing chain.

• If the camshaft timing chain can be moved side to side in excess of 0.430" replacement of the camshaft timing chain and sprockets is recommended during assembly. (see example below)

Remove the camshaft sprocket bolts

Remove the camshaft sprocket and camshaft timing chain

Remove the timing chain crankshaft sprocket from the crankshaft using a puller.

Remove the crankshaft harmonic balancer key from the crankshaft

Remove the balancer shaft drive gear from camshaft

Important note: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt.

• 1. Remove the balance shaft driven gear bolt from the balance shaft. Use a wrench in order to secure the balance shaft near to the balance shaft front bearing.

  2. Remove the balance shaft bolt

  3. Remove the wrench from the balance shaft

  4. Remove the balance shaft gear from the balance shaft

Remove the bolts and the balance shaft retainer.

Important note: The balance shaft and the balance shaft front bearing are serviced only as a package. Do Not remove the balance shaft front bearing from the balance shaft.

• Use a soft-faced hammer in order to remove the balance shaft from the engine block.

Remove the camshaft retainer bolts and the camshaft retainer plate

Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

• • Removal of the engine camshaft

  • Install three 5/16-18 x 4" bolts into the engine camshaft front bolt holes

  • Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings.

  • After the camshaft is removed remove the bolts from the camshaft.

GM 4.3 Camshaft installation procedure

Clean the engine camshaft with cleaning solvent

Dry the engine camshaft

Inspect the camshaft retainer plate for any damage or excessive wear. If the camshaft retainer plate is damaged or has excessive wear replace as necessary.

Inspect the camshaft bearings in the engine block for the correct fit to the engine block camshaft bearing bores, and they must not be loose in the engine block camshaft bearing bores.

If any camshaft bearing is excessively worn or scored, replace all the camshaft bearings.

Important note: I reusing the old camshaft inspect the camshaft for worn, scored, or damaged bearing journals (1), worn camshaft lobes (2), damaged bolt hole threads (3) or damaged camshaft sprocket locator pin (4)

Balance Shaft clean and inspect

Important note: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft.

1. Clean the following components in cleaning solvent: • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear

2. Dry the following components with compressed air: • The balance shaft (1) • The balance shaft retainer (2) • The balance shaft rear bearing • The balance shaft driven gear (4) • The balance shaft drive gear

3. Inspect the balance shaft bearings for the following: • Front ball bearing for damage or wear • Front ball bearing for smoothness of operation • Rear sleeve bearing for wear, scoring or other damage

4. Inspect the balance shaft (1) for the following: • Wear or scoring on the rear bearing journal • Damaged bolt hole threads • Damaged to the balance shaft driven gear locator pin

5. Inspect the balance shaft retainer (2) for wear or damage.

6. Inspect the balance shaft retainer bolts (3) for damaged threads.

7. Inspect the driven gear (4) for the following: • Excessive wear or damage • Nicks, burrs or scoring

8. Inspect the driven gear bolt (5) for damaged threads.

When replacing or reinstalling the camshaft the following procedure must be followed for the correct removal and installation of the balance shaft assembly when accessing the camshaft on the GM 4.3 Vortec style engine the proper sequence must be followed during installation according to GM guidelines or damage can occur to the engine.

Camshaft Installation

1. Apply motor assembly lube or clean engine oil or equivalent to the following components:

• The engine camshaft lobes

• The camshaft bearing journals

• The camshaft bearings

2. Install three 5/16-18 x 4.0 in. bolts into the engine camshaft front bolt holes.

Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

3. Use the bolts as a handle in order to help in aiding to install camshaft in the engine.

4. Remove the 3 bolts from the front of the engine camshaft when camshaft is fully installed into the engine.

5. Install the camshaft retainer and bolts. If reusing the bolts apply a threadlock compound to bolt threads.

6. Tighten the camshaft retainer bolts to 106 lb in.

Balance Shaft Installation

Important: The balance shaft and the balance shaft front bearing are serviced only as an assembly. Do not remove the balance shaft front bearing from the balance shaft.

1. Apply clean engine oil or equivalent to the balance shaft front bearing.

2. install the balance shaft assembly into the engine. The balance shaft assembly will not go all the way into the engine by hand it is a snug fit where the bearing seats. Use a soft headed hammer to tap the balance shaft into the engine until it is in the correct position.

3. Install the balance shaft retainer and bolts.

4. Tighten the balance shaft retainer bolts to 106 lb in.

5. Install the balance shaft drive gear onto the balance shaft.

6. Apply threadlock or equivalent to the threads of the balance shaft drive gear bolt.

7. Install the balance shaft drive gear bolt.

8. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing.

9. Install the balance shaft driven gear bolt.

10. Tighten the balance shaft driven gear bolt on the first pass to 15 lb ft. Tighten/turn the balance shaft drive gear bolt on the final pass an additional 35 degrees.

11. Remove the wrench from the balance shaft.

12. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case.

13. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time.

14. Rotate the engine camshaft so that the timing mark on the balance shaft drive gear is in the 12 o’clock position.

15. Remove the balance shaft drive gear.

16. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o’clock position.

17. Position the balance shaft drive gear onto the engine camshaft.

18. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned.

See example below

19. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline. See example below that is circled.

20. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.

21. Use the sleeve that will go around the diameter of the crankshaft or use a brass punch and small hammer to install the crankshaft sprocket onto crankshaft.

22. Rotate the crankshaft until the crankshaft sprocket alignment mark (dimple) is at the 12 o’clock position if the engine was in the normal upright position, not with engine upside down.

23. Install the camshaft sprocket with the alignment mark (dimple) is at the 6 o’clock position if the engine was in the normal upright position, not with engine upside down..

24. Install the camshaft sprocket and the camshaft timing chain.

25. Look to ensure that the crankshaft sprocket is aligned at the 12 o’clock position and the camshaft sprocket is aligned at the 6 o’clock position.

Important: Do not use a hammer to install the camshaft sprocket onto the camshaft. To do so may dislodge the expansion cup plug (camshaft rear bearing hole).

26. With the camshaft sprocket aligned with the dowel pin on the camshaft the bolt hole should align with the threads on the camshaft. Install the camshaft sprocket bolts.

27. Tighten the camshaft sprocket bolts to 18 lb ft.

28. Install the NEW engine front cover.

29. Install the engine front cover bolts. Tighten the engine front cover bolts to 106 lb in.

Crankshaft Balancer Installation

Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

1. Apply a small amount of adhesive silicone sealant or equivalent onto the crankshaft harmonic balancer keyway in order to seal the crankshaft harmonic balancer keyway and crankshaft joint.

3. Align the keyway of the crankshaft harmonic balancer with the crankshaft balancer key.

4. Install the crankshaft harmonic balancer onto the end of the crankshaft. and push on by hand as far as it will go.

Using a Harmonic Balancer installation tool like what is shown in the below example to properly install the Harmonic Balancer on the crankshaft.

After the harmonic balancer is properly installed and the harmonic balancer installation tool is removed Install the crankshaft balancer washer and the bolt.

Tighten the crankshaft balancer bolt to 70 lb ft.

Valve Lifter Installation

1. Apply engine assembly lube, engine oil lubricant or equivalent to the valve lifter rollers.

Important: If reusing the valve lifters, install the valve lifters in the original positions.

2. Install the valve lifters.

3. Install the valve lifter pushrod guides.

Tighten the valve lifter pushrod guide bolts to 16 12 lb ft.

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all General Motors 4.3 Vortec style Natural Gas Engines and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust. Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Emission set up knowlege for Natural Gas Engines

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools to include metric sockets

• Torque Wrench capable of torquing up to 106 (Inch Pounds)

• Torque Wrench capable of torquing 11 ft lbs (Foot Pounds)

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: