CAMSHAFT REMOVAL


  1. REMOVE ENGINE UNDER COVER

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. Remove the drain plug from the oil pan and drain engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E01

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  5. DRAIN POWER STEERING FLUID

  6. REMOVE CYLINDER HEAD GASKET

    Tech Tips

    Click here.

  7. DISCONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE


    1. A01CHED

      Disconnect the No. 2 oil reservoir to pump hose.

  8. REMOVE PRESSURE FEED HOSE


    1. A01CH96

      Using SST, separate the pressure feed hose.

      SST
      09023-12901

    2. Remove the gasket from the pressure feed hose.

  9. REMOVE VANE PUMP ASSEMBLY


    1. A01CHBBE03

      Remove the 2 bolts and remove the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  10. REMOVE WATER PUMP ASSEMBLY


    1. A01CIV9

      Remove the 8 bolts and water pump assembly.

  11. REMOVE INTAKE MANIFOLD


    1. A01CIOK

      Remove the 8 bolts and 2 nuts and remove the intake manifold.

  12. REMOVE EXHAUST MANIFOLD


    1. A01CHWE

      Remove the 3 bolts and remove the exhaust manifold heat insulator sub-assembly.

    2. A01CJ2L

      Remove the 8 nuts and remove the exhaust manifold.

  13. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Remove the bolt and remove the crankshaft position sensor.

  14. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Remove the bolt and remove the camshaft position sensor.

  15. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. A01CJ11E01

      Turn the crankshaft pulley until the grooves of the crankshaft damper and timing gear are aligned.

  16. REMOVE VACUUM PIPE


    1. Remove the union bolt and bolt and remove the vacuum pipe.

  17. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

      Remove the 3 bolts and remove the vacuum pump oil pipe sub-assembly.

  18. REMOVE VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Remove the 2 nuts and remove the vacuum pump assembly.

  19. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01CJ4U

      Remove the 2 union bolts, the 4 gaskets and the No. 4 fuel pipe sub-assembly.

  20. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJ7V

      Remove the nut and the fuel pipe clamp.

    2. Using SST, loosen the union nuts and remove the fuel filter to injection pump fuel pipe.

      SST
      09023-12901

  21. REMOVE FUEL DELIVERY PIPE


    1. A01CICS

      Remove the union bolt, the 2 gaskets and the fuel delivery pipe.

  22. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CIXS

      Remove the nut and the fuel pipe clamp.

    2. Remove the union bolt, the gasket and the fuel return pipe sub-assembly.

  23. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY

  24. REMOVE CRANKSHAFT PULLEY


    1. A01CIN3

      Using a 46 mm socket wrench, remove the nut, spacer and pulley.

      Tech Tips

      Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft.

  25. REMOVE FLYWHEEL HOUSING STAY LH


    1. Remove the 4 bolts and flywheel housing stay LH.

  26. REMOVE FLYWHEEL HOUSING STAY RH


    1. Remove the 4 bolts and flywheel housing stay RH.

  27. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 26 bolts.

    2. A01CHQHE01

      Insert the blade of SST between the crankcase and oil pan. Cut through the applied sealer and remove the oil pan.

      SST
      09032-00100

      Note

      Do not damage the contact surface of the cylinder block and oil pan.

  28. REMOVE TIMING GEAR CASE


    1. A01CJ31

      Remove the 15 bolts.

    2. Using a screwdriver with its tip wrapped in protective tape, pry out the timing gear case.

      Note

      Do not damage the contact surfaces of the timing gear case, cylinder block and cylinder head.

  29. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01CGS3E01

      Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.

  30. REMOVE CAMSHAFT


    1. A01CIVH

      Remove the 2 bolts and remove the camshaft.