CAMSHAFT (w/o 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 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.

      A01DNO9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  6. DISCONNECT INLET HEATER WATER HOSE


    1. A01DSEF

      Remove the bolt and disconnect the inlet heater water hose.

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


    1. A01DOGA

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

  8. REMOVE NO. 1 INTAKE PIPE


    1. A01DN3I

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A01DNIV

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

    5. A01DQ50

      Loosen the hose clamp of the intercooler air hose.

    6. A01DMJ4

      Remove the 2 bolts and No. 1 intake pipe.

  9. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ EGR System)


    1. A01DNIF

      Disconnect the throttle position sensor connector.

    2. A01DQM6

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

  10. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. A01DMQP

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  11. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  12. REMOVE INJECTION PIPE (w/ EGR System)

    Note


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

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


    1. A01DT2A

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

    2. A01DUQA

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

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  13. REMOVE AIR CONNECTOR STAY


    1. A01DRSE

      Remove the 3 bolts and air connector stay.

  14. DISCONNECT ENGINE WIRE (for LHD)


    1. A01DTKF

      Remove the 2 bolts.

    2. Detach the clamp and disconnect the engine wire.

  15. DISCONNECT ENGINE WIRE (for RHD)


    1. A01DOK7

      Remove the bolt and disconnect the engine wire.

  16. REMOVE EGR VALVE BRACKET (w/ EGR System)


    1. Remove the 2 nuts and EGR valve bracket.

  17. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)


    1. A01DRXH

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. A01DOAO

      Detach the wire harness clamp.

    3. A01DOLL

      Disconnect the 5 vacuum hoses.

    4. Remove the bolt and gas filter together with the gas filter bracket.

    5. A01DT6Y

      Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.

  18. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR System)


    1. A01DPM6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  19. REMOVE INTAKE AIR CONNECTOR (w/ EGR System)


    1. A01DOLG

      Remove the 3 bolts, intake air connector and 2 gaskets.

  20. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR System with EGR Cooler)


    1. A01DMW6

      Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.

    2. A01DOVN

      Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  21. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)


    1. A01DTMC

      Remove the 2 nuts and electric EGR control valve together with the No. 1 EGR pipe and gasket.

  22. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. A01DSG4E01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 2 bolts, electric EGR control valve and gasket.

  23. REMOVE EGR VALVE ADAPTER (w/ EGR System with EGR Cooler)


    1. A01DTMG

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  24. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)


    1. A01DPOB

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.

  25. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A01DS9F

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  26. REMOVE INJECTION PIPE (w/o EGR System)

    Note


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

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


    1. A01DT2A

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

    2. A01DUQA

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

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  27. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A01DQZJ

      Remove the 3 bolts and air connector stay.

  28. DISCONNECT ENGINE WIRE (w/o EGR System)


    1. A01DOC8

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A01DOKK

      for RHD:

      Remove the bolt and disconnect the engine wire.

  29. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A01DO8N

      Disconnect the throttle position sensor connector.

    2. A01DSBE

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  30. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A01DU30

        w/o EGR System:

        Disconnect the connector.

      2. A01DSOX

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A01DU9F

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A01DR0B

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DUDJ

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A01DNW0

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A01DSHRE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A01DUH7

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

  31. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DO5J

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01DUTCE06
      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. 4 injection pipe.

  32. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNQTE01
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

    2. Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.

  33. REMOVE WIRE HARNESS

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


    1. A01DS9D

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

  35. 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.

  36. REMOVE NOZZLE HOLDER SEAL


    1. A01DRNTE01

      Using a small screwdriver, remove the 4 holder seals by prying between each holder seal and the cutout part of the cylinder head cover.

  37. 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. A01DOIVE01

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

    2. A01DNBZ

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

  38. REMOVE INJECTOR ASSEMBLY


    1. A01DMJTE04
      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. A01DTYFE01

      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.

  39. REMOVE NO. 1 RADIATOR HOSE

    A01DTHF

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

      2. A01DPYW

        Disconnect the 2 oil cooler hoses from the radiator.

    5. A01DO7Q

      Loosen the 4 nuts holding the fluid coupling and fan.

    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 fan, and then remove the shroud together with the coupling fan.

      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.

  41. REMOVE NO. 1 TIMING BELT COVER


    1. A01DT7SE01

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

  42. 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.

  43. 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.

  44. 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.

  45. REMOVE NO. 2 TIMING BELT COVER


    1. A01DNYW

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

  46. 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.