CAMSHAFT REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and oil pan drain plug.

    4. Install a new gasket and the oil pan drain plug.

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

  5. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. A01CGQLE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug
      *4 Radiator Reservoir Assembly

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap sub-assembly, and then drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    3. Tighten the radiator drain cock plug by hand.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  6. DRAIN POWER STEERING FLUID

  7. REMOVE CYLINDER HEAD GASKET

    Click here

  8. REMOVE SUPPLY PUMP ASSEMBLY

    Click here

  9. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  10. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01CIV9

      Remove the 8 bolts and engine water pump assembly.

  11. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A01CHZD

      Remove the bolt and disconnect the cooler pipe.

    2. Disconnect the connector.

    3. A01CIOF

      Remove the 4 bolts and disconnect the cooler compressor assembly.

      Tech Tips

      With the hoses connected to the cooler compressor assembly, hang the cooler compressor assembly on the vehicle body with a rope.

  12. REMOVE IDLE PULLEY BRACKET


    1. A01CGLB

      Remove the 3 bolts and idle pulley bracket.

  13. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01CGMJ

      Remove the 3 bolts and No. 1 compressor mounting bracket.

  14. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CINB

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  15. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CIJX

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  16. REMOVE CRANKSHAFT PULLEY


    1. A01CIN3

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

      Tech Tips

      Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel sub-assembly to prevent the ring gear from turning together with the crankshaft.

  17. REMOVE FLYWHEEL HOUSING STAY LH


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

  18. REMOVE FLYWHEEL HOUSING STAY RH


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

  19. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 26 bolts.

    2. A01CJHGE03

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

      Note

      Do not damage the contact surfaces of the cylinder block or oil pan sub-assembly.

  20. REMOVE OIL SEPARATOR ASSEMBLY


    1. A01CHKC

      Remove the 5 bolts and oil separator assembly.

    2. Remove the 3 O-rings.

  21. REMOVE TIMING GEAR CASE


    1. A01CIDS

      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 or cylinder block.

  22. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01CHPDE02
      Text in Illustration
      *1 Protective Tape
      *2 Cloth

      Using a screwdriver with its tip wrapped in protective tape, pry out the timing chain or belt cover oil seal.

      Tech Tips

      Use a cloth to prevent damage to the timing gear case.

  23. REMOVE CAMSHAFT


    1. A01CIVH

      Remove the 2 bolts and camshaft.