CAMSHAFT REMOVAL


  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 UPPER RADIATOR SUPPORT SEAL


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

  3. REMOVE FRONT BUMPER COVER LOWER


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

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


    1. Remove the 4 bolts.

    2. A01DQWQ

      Unhook the engine under cover from the vehicle body as shown in the illustration.

  5. 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.

      A01DQCVE01
      Text in Illustration
      *1 Radiator Cap *2 Radiator Reservoir
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

      Tech Tips

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

    2. Drain the coolant by removing the radiator cap.

    3. Loosen the cylinder block drain cock plug.

    4. Loosen the cylinder block drain cock plug and drain the coolant from the engine.

      Note

      If coolant is not drained from the radiator drain cock plug, cylinder block drain cock plugs and radiator reservoir, clogging in the radiator or coolant leakage from the seal of the water pump may result.

  6. REMOVE FRONT FENDER APRON SEAL RH


    1. Remove the 4 clips and fender apron seal.

  7. REMOVE RESONATOR WITH AIR CLEANER CAP SUB-ASSEMBLY


    1. A01DTKZ

      Disconnect the sensor connector.

    2. Detach the wire harness clamp.

    3. Loosen the hose clamp and remove the resonator with air cleaner cap.

    4. A01DNS4

      Detach the 4 hook clamps, and then remove the air cleaner cap and resonator with air cleaner cap.

  8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  9. REMOVE AIR CLEANER CASE ASSEMBLY


    1. A01DM2P

      Remove the 3 bolts and air cleaner case.

  10. DISCONNECT WIRE HARNESS


    1. Remove the terminal cap.

    2. A01DLWP

      Remove the nut and generator wire.

    3. Disconnect the generator connector and cooler compressor connector.

    4. Detach the 4 wire harness clamps.

    5. A01DS4E

      for LHD:

      Detach the 4 wire harness clamps.

  11. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)


    1. A01DPMA

      Remove the bolt and wiring harness clamp bracket.

  12. REMOVE NO. 1 RADIATOR HOSE


    1. A01DMPR

      Detach the clamp and remove the No. 1 radiator hose.

    2. A01DNNF

      Remove the 2 nuts and hose clamp.

  13. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. A01DOPZ

      Disconnect the reservoir hose from the upper side of the radiator tank.

    2. Remove the 3 bolts and radiator reservoir.

  14. REMOVE FAN SHROUD


    1. A01DP8Q

      Loosen the 4 nuts holding the fluid coupling fan.

    2. Remove the vane pump V belt and the fan and generator V belt Click here.

    3. A01DPJX

      Remove the 2 bolts holding the fan shroud.

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

      Note

      Be careful not to damage the radiator core.

    5. Remove the fan pulley from the water pump.

  15. REMOVE VANE PUMP DRIVE PULLEY

    A01DOM9

    1. Remove the 4 bolts, vane pump drive pulley and cooler compressor drive pulley.

  16. REMOVE CRANKSHAFT PULLEY

    A01DTJ5E02
    Text in Illustration
    *a Hold
    *b Turn

    1. Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01DUDVE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      09950-60010   ( 09951-00490 )
      09950-40011   ( 09957-04010 )

  17. REMOVE IDLE PULLEY ASSEMBLY


    1. A01DNMZ

      Remove the 2 bolts and Idle pulley bracket.

  18. REMOVE TIMING BELT COVER


    1. A01DN4H

      Remove the 11 bolts, washers, timing belt cover, and 2 gaskets.

  19. REMOVE TIMING BELT GUIDE


    1. Remove the timing belt guide.

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Tech Tips

    If reusing the timing belt, draw a direction arrow on the timing belt (in the direction the belt move when the engine is running), and place matchmarks on the pulleys and timing belt.


    1. A01DNX4

      Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Text in Illustration
      A01DQPB Turn

      Note

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, and camshaft causing damage. Therefore, always set the crankshaft pulley is removed at the correct angle.

    2. A01DQUDE02

      Loosen the No. 1 timing belt idler bolt (A), and shift the idler to the left as far as possible.

      Text in Illustration
      A01DQPB Pry
      A01DMKT Move

    3. Tighten the No. 1 timing belt idler bolt (A), and then relieve the timing belt tension.

    4. Remove the timing belt.

  21. REMOVE TIMING BELT

    Tech Tips

    If reusing the timing belt, draw a direction arrow on the timing belt (in the direction the belt move when the engine is running), and place matchmarks on the pulleys and timing belt.


    1. A01DNX4

      Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Text in Illustration
      A01DQPB Turn

      Note

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, and camshaft causing damage. Therefore, always set the crankshaft pulley is removed at the correct angle.

    2. A01DQUDE02

      Loosen the No. 1 timing belt idler bolt (A), and shift the idler to the left as far as possible.

      Text in Illustration
      A01DQPB Pry
      A01DMKT Move

    3. Tighten the No. 1 timing belt idler bolt (A), and then relieve the timing belt tension.

    4. Remove the timing belt.

  22. REMOVE INTAKE PIPE


    1. A01DQT4E01

      Loosen the hose clamp and remove the 2 bolts and intake pipe.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 9 bolts, nut, cylinder head cover and gasket.

  24. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DPUUE05
      Text in Illustration
      A01DQPB Turn
      *1 Timing Mark
      *2 Protrusion

      Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01DOGKE01

      Using SST, loosen the pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    3. A01DSRSE01

      Using SST, separate the timing pulley from the camshaft.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

    4. Remove the pulley bolt and timing pulley.

    5. Remove the timing pulley woodruff key.

  25. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts and timing belt cover.

  26. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. Remove the 4 bolts, retainer and gasket.

  27. REMOVE CAMSHAFT OIL SEAL


    1. A01DOY6E01

      Using a screwdriver and hammer, tap out the oil seal.

  28. REMOVE CAMSHAFT


    1. A01DSL0E03
      Text in Illustration
      *1 Upward
      *2 Key Groove

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

    2. A01DQREE04

      Uniformly loosen and remove the 10 bearing cap bolts in several steps in the sequence shown in the illustration.

    3. Remove the 5 bearing caps and camshaft.

      Tech Tips

      Arrange the bearing caps in the correct order.