CAMSHAFT REMOVAL

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Make sure foreign matter does not enter the fuel path.


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE VACUUM TUBE CONNECTOR HOSE


    1. B007S35

      Slide the clamp and disconnect the vacuum tube connector hose from the vacuum pump assembly.

    2. Remove the 2 bolts and vacuum tube connector hose from the cylinder head sub-assembly and intake manifold.

  3. REMOVE NO. 16 WATER BY-PASS HOSE


    1. B007UJV

      Slide the 2 clamps and remove the No. 16 water by-pass hose from the No. 1 EGR cooler and No. 2 water by-pass pipe.

  4. REMOVE NO. 2 WATER BY-PASS PIPE


    1. B007Q6Z

      Disconnect the heater hose from the No. 2 water by-pass pipe.

    2. Remove the 2 bolts and No. 2 water by-pass pipe.

  5. REMOVE TURBO PRESSURE SENSOR


    1. B007SSH

      Disconnect the connector from the diesel turbo pressure sensor.

    2. Remove the bolt and diesel turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

  6. REMOVE GAS FILTER


    1. B007PAQ

      Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

    2. Remove the gas filter from the gas filter bracket.

  7. REMOVE GAS FILTER BRACKET


    1. B007S7B

      Remove the bolt and gas filter bracket from the diesel throttle body assembly.

  8. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. B007UU2

      Disconnect the connector and clamp.

    2. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

    3. B007V3W

      Disconnect the connector to remove the emission control valve wire from the diesel throttle body assembly.

  9. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007R0N

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B007QH0

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    4. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  10. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007VVV

      Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

    2. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    3. B007TLH

      Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

  11. REMOVE EGR VALVE BRACKET


    1. B007VJ5

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  12. REMOVE NO. 2 EGR PIPE


    1. B007TEN

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  13. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B007QH3

      Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. B007PGN

      Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. B007QR1

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  14. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the connector from the vacuum control valve set.

    2. B007SNQ

      Disconnect the 2 vacuum hoses from the vacuum control valve set and No. 2 EGR valve assembly.

    3. B007OKL

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  15. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

  16. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B007QHM

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  17. REMOVE HARNESS BRACKET


    1. B007RDU

      Remove the bolt and harness bracket.

  18. REMOVE NO. 1 FUEL PIPE


    1. B007QEC

      Remove the bolt, union bolt and gasket and disconnect the No. 1 fuel pipe from the cylinder head cover sub-assembly and exhaust fuel addition injector assembly.

    2. B007T63

      Disconnect the No. 4 fuel pipe and remove the No. 1 fuel pipe Click here.

  19. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B007WDQ

      Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.

    2. Remove the 4 union bolts and 4 gaskets.

    3. Remove the bolt and nozzle leakage pipe assembly.

  20. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

  21. REMOVE INJECTOR ASSEMBLY


    1. B007TDF

      Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps.

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

      When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

    3. Remove the O-ring from each injector assembly.

  22. REMOVE NOZZLE HOLDER GASKET


    1. B007QQT

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

  23. DISCONNECT BRACKET


    1. B007TGHE01

      Detach the 3 clamps and disconnect the 2 connectors from the bracket.

    2. Remove the 2 bolts and disconnect the bracket from the cylinder head sub-assembly.

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. B007QAN

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

  25. REMOVE VACUUM PUMP ASSEMBLY


    1. B007PHC

      Disconnect the No. 1 vacuum transmitting hose sub-assembly from the vacuum pump assembly.

    2. Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.

    3. Remove the 2 O-rings from the vacuum pump assembly.

  26. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. B007RJ4

      Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-assembly.

  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B007UOG

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut
      B007T7S Nozzle Holder Clamp Seat
    2. B007SGUE01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B007RJRE01
      Text in Illustration
      *a Timing Mark
      *b Paint Mark

      Align the timing mark of the crankshaft pulley and timing chain cover by rotating the crankshaft clockwise.

    2. Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/ compression).

    3. Place paint marks on the No. 2 chain sub-assembly.

  29. REMOVE TIMING CHAIN GUIDE


    1. B007UUA

      Remove the bolt and timing chain guide from the cylinder head sub-assembly.

  30. REMOVE CAMSHAFT


    1. B007UT9

      Remove the oil pump relief valve plug and gasket from timing chain cover.

    2. B007ROWE01
      Text in Illustration
      *a Stopper Plate
      *b Pin

      Insert a pin into stopper plate hole of the No. 2 chain tensioner assembly and lock the No. 2 chain tensioner assembly.

    3. B007T79E01
      Text in Illustration
      *1 No. 1 Camshaft
      *2 No. 2 Camshaft

      Hold the hexagonal portion of the camshaft with a wrench and loosen the 2 bolts from the No. 1 camshaft and No. 2 camshaft.

      CAUTION:

      Be careful not to damage the cylinder head sub-assembly with the wrench.

    4. B007S02

      Remove the 2 bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.

    5. B007UX1E01

      Using several steps, and remove the 20 bolt, No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-assembly.

    6. B007QW3

      Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.

    7. Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.

    8. B007W2S

      Remove the No. 2 camshaft from the camshaft timing sprocket.

    9. B007PLK

      Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

    10. B007P91

      Remove the No. 1 camshaft from the camshaft timing sprocket.

    11. B007TE0

      Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

    12. B007S2V

      Suspend the No. 2 chain sub-assembly with a string or equivalent.

      Tech Tips

      Be careful not to drop the No. 2 chain sub-assembly inside the timing chain cover assembly.