CAMSHAFT (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  4. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01DNWCE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  5. REMOVE FRONT WHEEL LH

  6. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and front fender apron seal LH.

  7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  8. DISCONNECT NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DSATE01
      Text in Illustration
      *1 No. 1 Engine Cover Hook
      *2 No. 3 Engine Cover Bracket

      Remove the 2 nuts.

    2. Detach the 2 No. 1 engine cover hooks from the No. 3 engine cover bracket and remove the No. 1 engine cover.

  9. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  10. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01DTH4

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  11. DISCONNECT INTERCOOLER AIR HOSE


    1. A01DQ82

      Loosen the hose clamp and disconnect the intercooler air hose.

  12. REMOVE NO. 1 INTAKE PIPE


    1. A01DO4G

      Disconnect the 2 connectors from the intake air temperature sensor and throttle position sensor.

    2. Detach the 2 wire harness clamps.

    3. A01DRSZ

      Loosen the 2 hose clamps of the No. 1 air hose.

    4. Remove the 2 bolts and No. 1 intake pipe.

  13. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DTWE

      Disconnect the throttle control motor connector.

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

  14. REMOVE INJECTOR DRIVER


    1. A01DS6O

      Disconnect the 4 connectors.

    2. Remove the 2 bolts and injector driver assembly.

  15. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01DUMX

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  16. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A01DTVF

      Disconnect the 3 vacuum switching valve connectors.

    2. A01DQV1

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DPF0

      Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.

    4. A01DO5A

      Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    5. A01DMMC

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DT9L

      Remove the bolt and No. 2 injection pipe clamp.

    2. A01DUVSE01
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  18. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DN54

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A01DOID

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A01DR7WE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  19. DISCONNECT HEATER WATER PIPE SUB-ASSEMBLY


    1. A01DSCK

      Detach the water by-pass hose clamp.

    2. Remove the bolt and disconnect the heater water pipe.

  20. DISCONNECT WATER BY-PASS HOSE


    1. Detach the 4 water by-pass hose clamps.

    2. Disconnect the No. 7 water by-pass hose labeled A in the illustration.

    3. Disconnect the No. 4 water by-pass hose labeled B in the illustration.

    4. Disconnect the No. 3 water by-pass hose labeled C in the illustration.

    5. Disconnect the No. 8 water by-pass hose labeled D in the illustration.

    6. Disconnect the No. 6 water by-pass hose labeled E in the illustration.

    7. Disconnect the No. 5 water by-pass hose labeled F in the illustration.

      A01DR6EE01

  21. REMOVE NO. 1 VACUUM TRANSMITTING PIPE


    1. A01DQGH

      Disconnect the vacuum hose from the intake manifold.

    2. Remove the bolt and No. 1 vacuum transmitting pipe.

  22. REMOVE WIRING HARNESS CLAMP BRACKET


    1. Disconnect the glow plug connector.

    2. A01DQ7X

      Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.

    3. A01DTDD

      Remove the bolt and wiring harness clamp bracket.

  23. REMOVE NO. 3 ENGINE COVER BRACKET


    1. A01DU9H

      Remove the 2 nuts and No. 3 engine cover bracket.

  24. REMOVE ENGINE COVER BRACKET INSULATOR


    1. A01DU9R

      Remove the 2 nuts and 2 engine cover bracket insulators.

  25. REMOVE NO. 4 ENGINE COVER BRACKET


    1. A01DND6

      Remove the bolt and No. 4 engine cover bracket.

  26. REMOVE AIR CONNECTOR STAY


    1. A01DM1Y

      Disconnect the 4 injector connectors and detach the 3 wire harness clamps.

    2. A01DQ91E01
      Text in Illustration
      *1 No. 1 Fuel Pipe

      Remove the bolt labeled A and disconnect the No. 1 fuel pipe from the air connector stay.

    3. Remove the 3 bolts and air connector stay.

  27. REMOVE EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY


    1. A01DN1V

      Disconnect the fuel pressure sensor connector from the common rail.

    2. Remove the 4 nuts, 3 bolts and EGR cooler with No. 2 EGR valve.

    3. Remove the 2 gaskets from the cylinder head and electric EGR control valve.

      A01DO92E01
      Text in Illustration
      *1 Gasket - -

  28. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Disconnect the electric EGR control valve connector.

    2. A01DU4IE01
      Text in Illustration
      *1 Intake Air Connector

      Remove the electric EGR control valve and gasket from the intake air connector.

  29. DISCONNECT WIRE HARNESS


    1. A01DU9L

      Remove the bolt and disconnect the wire harness.

    2. A01DOMZ

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  30. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01DUFS

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  31. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A01DQAM

      Remove the bolt and emission control valve bracket.

  32. REMOVE THROTTLE BODY BRACKET


    1. A01DPGW

      Remove the 3 bolts and throttle body bracket.

  33. REMOVE NO. 1 GAS FILTER


    1. A01DP2T

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  34. REMOVE GAS FILTER BRACKET


    1. A01DMQK

      Detach the clamp and disconnect the wire harness.

    2. A01DSGE

      Remove the bolt and gas filter bracket.

  35. REMOVE INTAKE AIR CONNECTOR


    1. A01DSTL

      Remove the 3 bolts, intake air connector and gasket.

  36. REMOVE NO. 1 FUEL PIPE


    1. Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

      A01DTAKE01
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A01DMKT Union Bolt - -

  37. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DSLU

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01DP3CE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  38. REMOVE NO. 2 FUEL PIPE


    1. A01DO4F

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A01DQPB Union Bolt
      A01DMKT Fuel Check Valve

    2. Remove the fuel check valve, gasket and No. 2 fuel pipe.

  39. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DPHI

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A01DMKT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  40. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNWG

      Remove the 3 bolts.

      Text in Illustration
      A01DMKT Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  41. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DRLR

      Remove the 4 bolts and No. 2 cylinder head cover.

  42. REMOVE VENTILATION PIPE


    1. A01DQZ6

      Type A

      Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.

    2. A01DM23E01
      Text in Illustration
      *A Type A
      *B Type B

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.

  43. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A01DRNTE01

      Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. A01DMOQ

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    3. A01DNBZ

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  44. REMOVE INJECTOR ASSEMBLY


    1. A01DNR5E04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01DN9SE02

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  45. REMOVE NO. 1 RADIATOR HOSE

    A01DT4C

  46. REMOVE FAN SHROUD


    1. A01DR1L

      Disconnect the No. 1 water by-pass hose and detach the 2 clamps from the fan shroud.

    2. Disconnect the No. 2 water by-pass hose from the radiator reservoir.

    3. Remove the 3 bolts and radiator reservoir.

    4. for Automatic Transmission:


      1. A01DPYW

        Remove the inlet and outlet oil cooler hoses and detach the clamp from the fan shroud.

      2. Disconnect the 2 oil cooler hoses from the radiator.

    5. A01DO7Q

      Loosen the 4 nuts holding the fan with fluid coupling.

    6. Remove the fan and generator V belt Click here.

    7. A01DPNM

      Remove the 2 bolts holding the fan shroud.

    8. Remove the 4 nuts for the fan with fluid coupling, and then remove the shroud together with the fan with fluid coupling.

      Note

      Be careful not to damage the radiator core.

    9. Detach the No. 2 water by-pass hose from the hose clamp on the fan shroud.

    10. A01DLWC

      Remove the No. 2 water by-pass hose from the water inlet.

    11. Remove the fan pulley from the water pump.

  47. REMOVE NO. 1 TIMING BELT COVER


    1. A01DT7SE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  48. REMOVE TIMING BELT


    1. A01DT33E05
      Text in Illustration
      *1 Timing Mark

      Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A01DMWCE01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A01DO9SE02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.

  49. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  50. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DT9YE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  51. REMOVE NO. 2 TIMING BELT COVER


    1. A01DNYW

      Remove the 4 bolts, nut and No. 2 timing belt cover.

  52. REMOVE CAMSHAFT


    1. A01DO09E03
      Text in Illustration
      *1 Key Groove

      Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

    2. A01DQBLE01

      Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

    3. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.