CAMSHAFT REMOVAL

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 1 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Make sure foreign matter does not enter the fuel path.


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE VACUUM TUBE CONNECTOR HOSE


    1. A003BXI

      Slide the clamp and disconnect the vacuum tube connector hose from the vacuum pump assembly.

    2. Remove the 2 bolts and vacuum tube connector hose from the cylinder head sub-assembly and intake manifold.

  3. REMOVE NO. 16 WATER BY-PASS HOSE


    1. A003E90

      Slide the 2 clamps and remove the No. 16 water by-pass hose from the No. 1 EGR cooler and No. 2 water by-pass pipe.

  4. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A003C6E

      Disconnect the heater hose from the No. 2 water by-pass pipe.

    2. Remove the 2 bolts and No. 2 water by-pass pipe.

  5. REMOVE TURBO PRESSURE SENSOR


    1. A003GP0

      Disconnect the connector from the diesel turbo pressure sensor.

    2. Remove the bolt and diesel turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

  6. REMOVE GAS FILTER


    1. A003HUS

      Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

    2. Remove the gas filter from the gas filter bracket.

  7. REMOVE GAS FILTER BRACKET


    1. A003G2M

      Remove the bolt and gas filter bracket from the diesel throttle body assembly.

  8. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A003GXD

      Disconnect the connector and clamp.

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

    3. A003E0O

      Disconnect the connector to remove the emission control valve wire from the diesel throttle body assembly.

  9. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003EH9

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. A003AZY

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    4. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  10. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003BTC

      Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

    2. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    3. A003EOI

      Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

  11. REMOVE EGR VALVE BRACKET


    1. A003DYA

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  12. REMOVE NO. 2 EGR PIPE


    1. A003FA5

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  13. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. A003DG1

      Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. A003B1N

      Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. A003C6J

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  14. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the connector from the vacuum control valve set.

    2. A003HOH

      Disconnect the 2 vacuum hoses from the vacuum control valve set and No. 2 EGR valve assembly.

    3. A003EZH

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  15. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003GKL

      Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly from the intake manifold.

  16. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A003H7Y

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  17. REMOVE HARNESS BRACKET


    1. A003FYC

      Remove the bolt and harness bracket.

  18. REMOVE NO. 1 FUEL PIPE


    1. A003BBJ

      Remove the bolt, union bolt and gasket and disconnect the No. 1 fuel pipe from the cylinder head cover sub-assembly and exhaust fuel addition injector assembly.

    2. A003HZ0

      Disconnect the No. 4 fuel pipe and remove the No. 1 fuel pipe Click here.

  19. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A003FRG

      Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.

    2. Remove the 4 union bolts and 4 gaskets.

    3. Remove the bolt and nozzle leakage pipe assembly.

  20. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    1. A003BH9E01

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      SST
      09245-11010
    2. A003D94

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note

      When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  21. REMOVE INJECTOR ASSEMBLY


    1. A003D7Y

      Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps.

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

      When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

    3. Remove the O-ring from each injector assembly.

  22. REMOVE NOZZLE HOLDER GASKET


    1. A003BQS

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

  23. DISCONNECT BRACKET


    1. A003HIR

      Detach the 2 clamps and disconnect the 2 connectors from the bracket.

    2. Remove the 2 bolts and disconnect the bracket from the cylinder head sub-assembly.

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. A003I4E

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

  25. REMOVE VACUUM PUMP ASSEMBLY


    1. A003D6M

      Disconnect the No. 1 vacuum transmitting hose sub-assembly from the vacuum pump assembly.

    2. Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.

    3. Remove the 2 O-rings from the vacuum pump assembly.

  26. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. A003AZB

      Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-assembly.

  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003CXE

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      A003DCD Bolt
      A003GWQ Nut
      A003G0E Nozzle Holder Clamp Seat
    2. A003BSPE01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A003HEYE01
      Text in Illustration
      *a Timing Mark
      *b Paint Mark

      Align the timing mark of the crankshaft pulley and timing chain cover by rotating the crankshaft clockwise.

    2. Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/ compression).

    3. Place paint marks on the No. 2 chain sub-assembly.

  29. REMOVE TIMING CHAIN GUIDE


    1. A003DY7

      Remove the bolt and timing chain guide from the cylinder head sub-assembly.

  30. REMOVE CAMSHAFT


    1. A003HQD

      Remove the oil pump relief valve plug and gasket from timing chain cover.

    2. A003BLVE01
      Text in Illustration
      *a Stopper Plate
      *b Pin

      Insert a pin into stopper plate hole of the No. 2 chain tensioner assembly and lock the No. 2 chain tensioner assembly.

    3. A003EZZE01
      Text in Illustration
      *1 No. 1 Camshaft
      *2 No. 2 Camshaft

      Hold the hexagonal portion of the camshaft with a wrench and loosen the 2 bolts from the No. 1 camshaft and No. 2 camshaft.

      CAUTION:

      Be careful not to damage the cylinder head sub-assembly with the wrench.

    4. A003AGH

      Remove the 2 bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.

    5. A003CI0E01

      Using several steps, and remove the 20 bolt, No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-assembly.

    6. A003DU2

      Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.

    7. Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.

    8. A003I5H

      Remove the No. 2 camshaft from the camshaft timing sprocket.

    9. A003DKG

      Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

    10. A003DDN

      Remove the No. 1 camshaft from the camshaft timing sprocket.

    11. A003BIQ

      Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.

    12. A003DH3

      Suspend the No. 2 chain sub-assembly with a string or equivalent.

      Tech Tips

      Be careful not to drop the No. 2 chain sub-assembly inside the timing chain cover assembly.