Frelander 2. Manual — part 196
Item
Part Number
Description
1
-
High Pressure (HP) fuel injector (4 off)
2
-
Structural camshaft cover
3
-
Exhaust camshaft
4
-
Hydraulic lash adjuster and roller finger rocker (16 off)
5
-
Split taper collets (32 off)
6
-
Upper spring guide (16 off)
7
-
Valve spring (16 off)
8
-
Lower spring guide (16 off)
9
-
Cylinder head
10
-
Gasket
11
-
Exhaust valve (8 off)
12
-
Intake valve (8 off)
13
-
Glow plug (4 off)
14
-
Cylinder head bolt (10 off)
15
-
Intake camshaft
16
-
Cylinder head front oil seal
Cylinder Head and Structural Camshaft Cover
Item
Part Number
Description
A
-
Structural camshaft cover
B
-
Cylinder head
1
-
Injector mounting clamp bolt (4 off)
2
-
Injector mounting clamp (4 off)
3
-
Dowel (4 off)
4
-
Gasket
5
-
Exhaust camshaft
6
-
Camshaft bearing housing (5 per camshaft)
7
-
Intake camshaft
8
-
Intake port raised profile (at each intake port)
9
-
Intake valve
10
-
Exhaust valve
11
-
Cooling channel
12
-
Cooling channel
13
-
Oil supply port
14
-
Injector bore
15
-
PCV ports
The cylinder head and structural camshaft cover are manufactured to form mating parts. The parts are milled in a single
operation and accurately positioned with 2 alignment sleeves. The 2 components must always be installed together, and
not renewed as separate components. The cylinder head and camshaft cover are sealed to each other during manufacture
with a gasket and silicone based sealant, and are secured with 27 bolts. An oil seal installed at the front of the cylinder
head provides sealing of the exhaust camshaft housing. The open ports at the rear of the cylinder head are sealed with
the vacuum pump and high-pressure fuel pump sealing rings.
Two alignment sleeves correctly locate the cylinder head and gasket to the cylinder block. The cylinder head is secured to
the cylinder block with 10 deep-seated bolts.
• NOTE: The cylinder head bolts are not accessible with the structural camshaft cover installed.
• NOTE: The cylinder head is not to be reworked.
The cylinder head is manufactured from aluminum alloy, having valve seats and guides made of sintered steel. The
cylinder head is precisely machined and milled to incorporate the 4 combustion chambers, camshaft lower bearing
housings, oil drillings and coolant galleries, and the air intake, valve timing and fuel system component bores and
housings.
The design of the cylinder head maximizes air flow and swirl in the combustion chambers. The 2 intake valve seats are
machined with raised profiles that act to promote swirl of the intake air flow. Combined with the action of the intake
manifold helical port, the swirl effect of the 2 intake port profiles allows the air and injected fuel to completely mix, and
reach the outer edge of the combustion chamber.
The structural camshaft cover is manufactured from aluminum alloy, and is machined on the upper surface with the
camshaft upper bearing housings. The cover is also formed with 4 intake air filling tracts, fuel injector bores and orifices
for the cylinder head cover PCV components. The intake air tracts join the intake air manifold to the cylinder head intake
filling ports.
The cylinder head also provides the mounting locations for the following:
Front engine mounting
Front and rear engine lifting eyes
Intake and exhaust manifolds
EGR valve and cooler
Fuel filter support bracket
Thermal control module
Vacuum pump and high-pressure fuel pump.
Cylinder Head Gasket
Item
Part Number
Description
1
-
Engine type identification
2
-
Gasket thickness identification
3
-
Gasket thickness identification
The cylinder head gasket is made from laminated metal and is available in 4 different thicknesses. Lugs formed on the
side of the gasket are 'dot' marked to identify the engine type, and the thickness of the gasket installed. A new gasket is
selected based on the piston protrusion measurement from the cylinder block.
For further details on cylinder head gasket selection, refer to the relevant Service Repair Procedures (SRP) manual.
Camshafts
Item
Part Number
Description
1
-
Exhaust camshaft
2
-
Intake camshaft
3
-
No. 3 bearing (end-float control)
4
-
Single row timing chain
5
-
Exhaust camshaft pulley
The intake and exhaust camshafts are manufactured from cast-iron. The 2 camshafts are mounted between the structural
camshaft cover and cylinder head, with each camshaft located in 5 machined bearing housings. Shell bearings are not used
in the bearing housings, the camshafts run directly in the aluminum bearing. Lateral movement of the camshafts is
controlled by No. 3 camshaft bearing, and is not adjustable. The bearing is manufactured on both camshafts to provide the
correct end-float.
• NOTE: In production, the camshaft end-float is 0.070 mm to 0.168 mm (0.003 in to 0.007 in). In service, if the end-float
is out of specification the camshaft(s) and/or cylinder head and structural camshaft cover may require renewal.
Each camshaft has 8 machined lobes formed in pairs along the length of the camshaft. The camshaft lobes operate the
inlet and exhaust valves through hydraulic lash adjusters and roller-type finger levers
A spur gear with 19 teeth is formed on the front end of each camshaft. The 2 gears are joined by a 40-link single row
timing chain. The 2 camshaft gears are marked with a timing mark that coincides with the 2 colored links on the camshaft
timing chain. A drive slot is formed in the rear end of each camshaft to provide the drive to the flange mounted vacuum
pump and high-pressure fuel pump. The vacuum pump is driven by the inlet camshaft; the high-pressure fuel pump is
driven by the exhaust camshaft.
The exhaust camshaft is driven by the crankshaft drive gear via a toothed timing belt. The exhaust camshaft pulley
contains 42 teeth and is keyed and bolted to the front of the exhaust camshaft. The intake camshaft is driven by the
exhaust camshaft via the single row chain.
The exhaust camshaft pulley is manufactured with cut-outs and a notch in the center hub. The cut-outs form the target
area for the CMP sensor. The notch provides the location for a camshaft timing pin special tool. The special tool is used in
conjunction with other special tools to set the exhaust camshaft during engine timing.
For further details on setting the engine valve timing, refer to the relevant Service Repair Procedures (SRP) manual.
Engine Valve Timing
The valve timing values are shown in the following table:
Valve
Position
Inlet valve opens
15 degrees BTDC
Inlet valve closes
12 degrees ABDC
Exhaust valve opens
23 degrees BBDC
Exhaust valve closes
17 degrees ATDC
Key:
BTDC = Before Top Dead Center
ABDC = After Bottom Dead Center
BBDC = Before Bottom Dead Center
ATDC = After Top Dead Center.
Camshaft Position (CMP) Sensor
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