CAMSHAFT(w/ DPF) REMOVAL

PROCEDURE

1. INSTALL ENGINE STAND

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2. REMOVE ENGINE COVER BRACKET

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3. REMOVE GENERATOR ASSEMBLY

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4. REMOVE GENERATOR BRACKET

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5. REMOVE EGR WITH COOLER PIPE ASSEMBLY

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6. REMOVE NO. 1 EGR COOLER BRACKET

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7. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)

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8. REMOVE WIRING HARNESS CLAMP BRACKET (for RHD)

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9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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10. REMOVE ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

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11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

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12. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

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13. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

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14. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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15. REMOVE NO. 1 FUEL HOSE

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16. DISCONNECT NO. 2 FUEL HOSE

    

    
    

    1. Slide the hose clip and disconnect the No. 2 fuel hose from the No. 2 nozzle leakage pipe.

17. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

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18. REMOVE FUEL PUMP PROTECTOR

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19. REMOVE SUPPLY PUMP ASSEMBLY

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20. REMOVE NO. 2 OIL COOLER HOSE

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21. REMOVE NO. 4 WATER BY-PASS HOSE

    

    
    

    1. Disengage the clamp to separate the No. 4 water by-pass hose from the common rail assembly.

    2. Slide the hose clip and remove the No. 4 water by-pass hose from the water inlet pipe.

22. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    

    
    

    1. Slide the hose clip and disconnect the No. 6 water by-pass hose from the water by-pass pipe sub-assembly.

    2. 

       Slide the hose clip and disconnect the water by-pass hose from the tube connector.

    3. 

       Slide the hose clip and disconnect the oil cooler hose from the water by-pass pipe sub-assembly.

    4. 

       Remove the 3 bolts and water by-pass pipe sub-assembly from the No. 2 turbocharger stay, cylinder head sub-assembly, cylinder block sub-assembly and water inlet housing.

    5. Remove the water by-pass pipe O-ring from the water by-pass pipe sub-assembly.

23. REMOVE VACUUM PUMP ASSEMBLY

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24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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26. REMOVE ENGINE MOUNTING BRACKET RH

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27. REMOVE NO. 2 TIMING CHAIN COVER

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28. REMOVE CAMSHAFT POSITION SENSOR

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29. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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30. DISCONNECT WATER INLET HOSE LH

    

    
    

    1. Slide the hose clip and disconnect the water inlet hose LH from the water inlet.

31. REMOVE TIMING CHAIN COVER ASSEMBLY

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32. REMOVE TIMING CHAIN COVER OIL SEAL

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33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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34. REMOVE CHAIN TENSIONER SLIPPER

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35. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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36. REMOVE CHAIN SUB-ASSEMBLY

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37. REMOVE CAMSHAFT

    

    Text in Illustration

    *1	No. 1 Camshaft Bearing Cap
    *2	No. 2 Camshaft Bearing Cap
    *3	No. 3 Camshaft Bearing Cap
    *4	No. 4 Camshaft Bearing Cap

    
    

    1. Remove the 10 bolts from the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing caps and No. 4 camshaft bearing cap by loosening them in the order shown in the illustration, and then remove the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing caps and No. 4 camshaft bearing cap from the cylinder head sub-assembly.

       Note

       
       

       • Using several steps, uniformly loosen the bolts while keeping the camshaft level.

       • Do not remove No. 3 camshaft bearing cap.

    2. Remove the camshaft from the cylinder head sub-assembly.