CAMSHAFT(w/o DPF) REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

When replacing an injector (including interchanging injectors between cylinders), common rail, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.

PROCEDURE


  1. CHECK INJECTOR COMPENSATION CODE

    Click here

  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

    Click here

  5. DRAIN CLUTCH FLUID (for Manual Transmission)

  6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

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

    Click here

  9. DRAIN ENGINE COOLANT

    Click here

  10. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  11. REMOVE NO. 3 ENGINE ROOM WIRE

    Click here

  12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

    Click here

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  15. REMOVE INTAKE AIR CONNECTOR

    Click here

  16. REMOVE V-RIBBED BELT (w/ Viscous Heater)

    Click here

  17. REMOVE NO. 1 IDLER PULLEY (w/ Viscous Heater)

    Click here

  18. REMOVE NO. 3 IDLER PULLEY (w/ Viscous Heater)

    Click here

  19. REMOVE V-RIBBED BELT

    Click here

  20. REMOVE FRONT FENDER APRON SEAL FRONT RH

    Click here

  21. REMOVE FRONT FENDER APRON SEAL REAR RH

    Click here

  22. REMOVE FRONT FENDER APRON SEAL FRONT LH

    Click here

  23. REMOVE FRONT FENDER APRON SEAL REAR LH

    Click here

  24. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  25. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  26. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  27. REMOVE VANE PUMP ASSEMBLY

    Click here

  28. REMOVE OIL COOLER TUBE (for Automatic Transmission)

    Click here

  29. REMOVE FAN SHROUD WITH FAN

    Click here

  30. REMOVE FRONT FENDER MAIN SEAL LH

    Click here

  31. REMOVE FRONT FENDER MAIN SEAL RH

    Click here

  32. REMOVE FRONT WIPER ARM LH

    Click here

  33. REMOVE FRONT WIPER ARM RH

    Click here

  34. REMOVE HOOD TO COWL TOP SEAL

    Click here

  35. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  36. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  37. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  38. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  39. REMOVE NO. 1 AIR HOSE

    Click here

  40. REMOVE NO. 2 AIR HOSE

    Click here

  41. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  42. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  43. REMOVE CLUTCH HOSE (for Manual Transmission)

    Click here

  44. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  45. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  46. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  47. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  48. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  49. REMOVE NO. 3 AIR TUBE

    Click here

  50. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  51. REMOVE NO. 4 AIR TUBE

    Click here

  52. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  53. REMOVE VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

    Click here

  54. REMOVE NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  55. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  56. DISCONNECT FUEL HOSE

    Click here

  57. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B001Z7S

        Disconnect the 4 connectors from the injector driver.

      2. Remove the 2 connectors and detach the wire harness holder from the relay block.

      3. Remove the bolt and disconnect the ground wire.

      4. Disconnect the wire harness from the wire harness clamp holder.

      5. B001X96E02

        Remove the bolt and disconnect the ground wire from the body panel.

      6. Using a clip remover, detach the ground wire clamp labeled A from the relay block side.

      7. Disconnect the wire harness from the wire harness clamp holder labeled B.

      8. B001YAG

        Disconnect the 4 connectors.

      9. Using a clip remover, detach the 3 wire harness clamps.

      10. B001VWP

        Disconnect the 2 connectors.

      11. Using a clip remover, detach the 3 wire harness clamps.

      12. B001Z8KE02

        Disconnect the 8 connectors.

      13. Remove the 2 bolts labeled A and disconnect the engine wire protector.

      14. Remove the bolt labeled B and engine wire harness bracket.

      15. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. B001X2O

        Disconnect the 4 connectors.

      2. Using a clip remover, detach the 5 wire harness clamps.

      3. B001ZASE02

        Disconnect the 7 connectors.

      4. Using a clip remover, detach the wire harness clamp.

      5. Remove the 3 bolts labeled A and disconnect the wire harness protector.

      6. Remove the bolt labeled B and wire harness bracket.

      7. Remove the nut labeled C and glow plug wire harness.

    3. B001Y7JE01

      for LHD:


      1. Disconnect the 4 connectors, and detach the wire harness tab labeled A from the relay block.

      2. Disconnect the ECM connector.

      3. Disconnect the wire harness from the wire harness clamp holder.

    4. for RHD:


      1. B001ZYX

        Disconnect the wire harness from the wire harness clamp holder.

      2. B001YLVE02

        Disconnect the 4 connectors, and detach the wire harness tab labeled A from the relay block.

      3. Disconnect the ECM connector.

      4. Disconnect the wire harness from the wire harness clamp holder.

  58. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  59. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  60. REMOVE INJECTION PIPE LH

    Click here

  61. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  62. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  63. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  64. REMOVE INJECTION PIPE RH

    Click here

  65. REMOVE NO. 2 IDLER PULLEY (w/ Viscous Heater)

    Click here

  66. REMOVE NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  67. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)

    Click here

  68. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  69. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)

    Click here

  70. DISCONNECT NO. 2 VENTILATION HOSE

    Click here

  71. DISCONNECT NO. 3 VENTILATION HOSE

    Click here

  72. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)

    Click here

  73. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)

    Click here

  74. REMOVE NOZZLE HOLDER SEAL RH

    Click here

  75. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  76. REMOVE NOZZLE HOLDER GASKET RH

    Click here

  77. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  78. REMOVE NOZZLE HOLDER SEAL LH

    Click here

  79. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  80. REMOVE NOZZLE HOLDER GASKET LH

    Click here

  81. REMOVE FUEL INJECTOR RH

    Click here

  82. REMOVE FUEL INJECTOR LH

    Click here

  83. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. B001W5XE06
      *1 Arrow

      Rotate the crankshaft clockwise, and align the No. 1 camshaft timing sprocket arrow with the cylinder head upper surface.

    2. B001ZIB

      Using a 10 mm hexagon wrench, remove the taper screw plug.

    3. Fix the No. 1 chain tensioner in place.


      1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

      2. Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

      3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        B001VNGE02
        *1 Stopper Plate
    4. B001XILE01

      Using SST, hold the pump drive shaft gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    5. Remove the 2 bolts.

    6. B001X2TE07
      *1 Arrow

      Rotate the crankshaft clockwise 360° so that the No. 1 camshaft timing sprocket arrow points at the No. 1 camshaft center.

      Note

      Do not rotate the crankshaft counterclockwise in order to align the sprocket arrow and camshaft center.

    7. B001XG6E07
      *1 Matchmark

      Place matchmarks on the No. 1 timing chain and No. 1 camshaft timing sprocket.

    8. Place matchmarks on the No. 1 and No. 2 camshaft gears.

    9. B001YQ2E01

      Using SST, hold the pump drive shaft gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    10. Remove the 2 bolts and pump drive shaft gear.

    11. Disconnect the No. 1 timing chain and No. 1 camshaft timing sprocket from the No. 2 camshaft.

      Note


      • Do not remove the No. 1 camshaft timing sprocket from the No. 1 timing chain.

      • Do not rotate the crankshaft until the No. 1 timing chain and No. 1 camshaft timing sprocket are connected to the No. 2 camshaft.

      Tech Tips

      If fixing the No. 1 camshaft timing sprocket in place, pass a rope or equivalent through one of the No. 1 camshaft timing sprocket holes and tie the sprocket and chain together.

    12. B001WYP

      Turn the No. 1 camshaft clockwise so that the bolt is easier to install.

    13. B001YA9

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Do not drop the bolt into the engine.

      Tech Tips

      If it is difficult to install the bolt, rotate the camshaft so that the bolt is easier to install.

    14. B001YW0

      Loosen the 2 union bolts.

    15. B001VOFE02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    16. B001YWC

      Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

    17. B001ZQY

      Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    18. B001XLC

      Remove the No. 1 and No. 2 camshafts.

  84. REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. B001WBE

      Rotate the crankshaft clockwise, and align the No. 2 camshaft timing sprocket arrow with the cylinder head upper surface.

    2. B001VY9

      Using a 10 mm hexagon wrench, remove the taper screw plug.

    3. Fix the No. 2 chain tensioner in place.


      1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

      2. Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

      3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        B001W1BE02
        *1 Stopper Plate
    4. B001YV5E03

      Using SST, hold the No. 2 camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    5. Remove the 2 bolts.

    6. B001YZCE06
      *1 Arrow

      Rotate the crankshaft clockwise 360° so that the No. 2 camshaft timing sprocket arrow points at the No. 4 camshaft center.

    7. B001YUYE06
      *1 Matchmark

      Place matchmarks on the No. 2 timing chain and No. 2 camshaft timing sprocket.

    8. Place matchmarks on the No. 3 and No. 4 camshaft gears.

    9. B001YV5E03

      Using SST, hold the No. 2 camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    10. Remove the 2 bolts, and disconnect the No. 2 timing chain and No. 2 camshaft timing sprocket from the No. 3 camshaft.

      Note


      • Do not remove the No. 2 camshaft timing sprocket from the No. 2 timing chain.

      • Do not rotate the crankshaft until the No. 2 timing chain and No. 2 camshaft timing sprocket are connected to the No. 3 camshaft.

      Tech Tips

      If fixing the No. 2 camshaft timing sprocket in place, pass a rope or equivalent through one of the No. 2 camshaft timing sprocket holes and tie the sprocket and chain together.

    11. B001WDI

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Do not drop the bolt into the chain cover.

      Tech Tips

      If it is difficult to install the bolt, rotate the camshaft so that the bolt is easier to install.

    12. B001VYS

      Loosen the 2 union bolts.

    13. B001XZ0E02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    14. B001X18

      Remove the 2 union bolts and No. 3 and No. 4 oil feed pipes.

    15. B001ZWS

      Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    16. B001VRV

      Remove the No. 3 and No. 4 camshafts.