CAMSHAFT REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe subassembly 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

    • 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.

PROCEDURE


  1. 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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE ENGINE ASSEMBLY

    Click here

  4. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT OIL SEAL RETAINER

    Click here

  6. REMOVE WATER HOSE SUB-ASSEMBLY

    Click here

  7. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  8. REMOVE NO. 3 ENGINE COVER BRACKET

    Click here

  9. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  10. REMOVE NO. 1 FUEL PIPE

    Click here

  11. REMOVE VENTILATION PIPE SUB-ASSEMBLY

    Click here

  12. DISCONNECT NO. 4 WATER BY-PASS HOSE

    Click here

  13. DISCONNECT NO. 5 WATER BY-PASS HOSE

    Click here

  14. REMOVE NO. 1 INJECTOR HOLDER

    Click here

  15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  16. REMOVE DIFFERENTIAL PRESSURE SENSOR

    Click here

  17. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    Click here

  18. REMOVE NO. 1 VACUUM PIPE

    Click here

  19. REMOVE NO. 2 VACUUM PIPE

    Click here

  20. REMOVE PIPE CLAMP

    Click here

  21. REMOVE ENGINE COVER BRACKET

    Click here

  22. REMOVE AIR TUBE ASSEMBLY

    Click here

  23. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  24. REMOVE GAS FILTER

    Click here

  25. REMOVE TURBO PRESSURE SENSOR

    Click here

  26. REMOVE EGR VALVE BRACKET

    Click here

  27. REMOVE NO. 2 EGR PIPE

    Click here

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

    Click here

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

    Click here

  30. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  31. REMOVE VACUUM CONTROL VALVE SET

    Click here

  32. REMOVE NO. 1 EGR COOLER WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  33. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  34. REMOVE HARNESS BRACKET

    Click here

  35. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

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

    Click here

  37. REMOVE INJECTOR ASSEMBLY

    Click here

  38. REMOVE NOZZLE HOLDER GASKET

    Click here

  39. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  40. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  41. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. B001HKHE02
      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.

  42. REMOVE TIMING CHAIN GUIDE


    1. B001HR1

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

  43. REMOVE CAMSHAFT


    1. B001GST

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

    2. B001DWDE02
      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. B001HUAE02
      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. B001HTS

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

    5. B001DLIE02

      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. B001DL1

      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. B001F61

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

    9. B001CHJ

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

    10. B001HTZ

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

    11. B001D45

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

    12. B001F3E

      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.