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 and gasket 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 a union nut wrench (19 mm), separate the pressure feed hose.

    2. Remove the gasket from the pressure feed hose.

  9. REMOVE VANE PUMP ASSEMBLY


    1. A01CHBBE03

      Remove the 2 bolts and 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 exhaust manifold heat insulator sub-assembly.

    2. A01CJ2L

      Remove the 8 nuts and exhaust manifold.

  13. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Remove the bolt and crankshaft position sensor.

  14. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Remove the bolt and camshaft position sensor.

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CJ11E01

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips

      Make sure that there is free play in the No. 1 cylinder rocker arms and that there is no free play in the No. 4 cylinder rocker arms.

  16. REMOVE VACUUM PIPE


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

  17. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

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

  18. REMOVE VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Remove the 2 nuts and vacuum pump assembly.

  19. REMOVE FUEL PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts and nut, and then remove the 3 fuel pipe clamps.

    2. Remove the union bolt and gaskets, and then remove the fuel pipe sub-assembly.

  20. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. Separate the wire harness connector.

    2. A01CHXB

      Separate the 2 wire harness clamps.

    3. A01CJB8

      Remove the nut and fuel pipe clamp.

    4. Using a union nut wrench (17 mm), loosen the 2 union nuts.

    5. Remove the fuel filter to injection pump fuel pipe.

  21. REMOVE NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY


    1. A01CIVD

      Remove the nut and the fuel pipe clamp.

    2. Remove the 2 union bolts, the 4 gaskets and the No. 3 nozzle leakage pipe sub-assembly.

  22. REMOVE COMMON RAIL ASSEMBLY


    1. A01CIXW

      Separate the fuel pressure sensor connector.

    2. Loosen the clip and separate the fuel hose.

    3. Remove the 2 bolts and the common rail assembly.

  23. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNN

      Remove the 2 union bolts and 5 gaskets.

    2. Remove the fuel return pipe sub-assembly.

  24. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01CIH3

      Separate the 2 connectors.

    2. Remove the bolt, and then separate the holder clip.

    3. A01CIHL

      Remove the 4 bolts and the supply pump assembly.

    4. Remove the O-ring from the timer cover.

  25. 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.

  26. REMOVE FLYWHEEL HOUSING STAY LH


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

  27. REMOVE FLYWHEEL HOUSING STAY RH


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

  28. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 26 bolts.

    2. A01CHQH

      Insert the blade of an oil pan seal cutter between the crankcase and oil pan. Cut through the applied sealer and remove the oil pan.

      Note

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

  29. 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.

  30. 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.

  31. REMOVE CAMSHAFT


    1. A01CIVH

      Remove the 2 bolts and camshaft.