CAMSHAFT(w/ DPF) REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

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

Note

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. CHECK INJECTOR COMPENSATION CODE

    Click here

  2. PRECAUTION

    Note

    After turning the engine 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.


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. DRAIN ENGINE OIL

    Click here

  6. REMOVE FRONT WHEEL

  7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  8. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

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

    Click here

  10. DRAIN ENGINE COOLANT

    Click here

  11. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  12. REMOVE NO. 3 ENGINE ROOM WIRE

    Click here

  13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  15. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  16. REMOVE INTAKE AIR CONNECTOR

    Click here

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

    Click here

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

    Click here

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

    Click here

  20. REMOVE V-RIBBED BELT

    Click here

  21. REMOVE FRONT FENDER APRON SEAL FRONT RH

    Click here

  22. REMOVE FRONT FENDER APRON SEAL REAR RH

    Click here

  23. REMOVE FRONT FENDER APRON SEAL FRONT LH

    Click here

  24. REMOVE FRONT FENDER APRON SEAL REAR LH

    Click here

  25. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  26. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  27. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  28. REMOVE VANE PUMP ASSEMBLY

    Click here

  29. REMOVE OIL COOLER TUBE

    Click here

  30. REMOVE FAN SHROUD WITH FAN

    Click here

  31. REMOVE INTERCOOLER ASSEMBLY

    Click here

  32. REMOVE NO. 1 AIR HOSE

    Click here

  33. REMOVE NO. 2 AIR HOSE

    Click here

  34. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  35. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  36. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  37. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  40. REMOVE NO. 3 AIR TUBE

    Click here

  41. REMOVE AIR CLEANER PIPE

    Click here

  42. REMOVE NO. 4 AIR TUBE

    Click here

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

    Click here

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

    Click here

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

    Click here

  46. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  47. DISCONNECT FUEL HOSE

    Click here

  48. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B0019MZ

        Disconnect the 7 connectors from the injector driver.

      2. Remove the 4 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. B0019FEE02

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

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

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

      8. B0019OH

        Disconnect the 4 connectors.

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

      10. B001AGS

        Disconnect the 2 connectors.

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

      12. B001AIDE02

        Disconnect the 8 connectors.

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

      14. Using a clip remover, detach the wire harness clamp labeled D.

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

      16. for RHD:

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

    2. RH Side:


      1. B0018MV

        Disconnect the 4 connectors.

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

      3. B0019O3E02

        Disconnect the 7 connectors.

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

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

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

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

    3. B00183ZE02

      for LHD:


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

      2. Disconnect the ECM connector.

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

    4. for RHD:


      1. B0018TF

        Disconnect the wire harness from the wire harness clamp holder.

      2. Remove the bolt and wire harness clamp holder.

      3. B0018E3E02

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

      4. Disconnect the ECM connector.

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

  49. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  50. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

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

    Click here

  52. REMOVE CYLINDER HEAD COVER SILENCER LH

    Click here

  53. REMOVE NO. 4 NOZZLE LEAKAGE PIPE

    Click here

  54. REMOVE INJECTION PIPE SUB-ASSEMBLY LH

    Click here

  55. REMOVE NO. 2 FUEL PIPE

    Click here

  56. REMOVE NO. 5 NOZZLE LEAKAGE PIPE

    Click here

  57. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

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

    Click here

  59. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  60. REMOVE CYLINDER HEAD COVER SILENCER RH

    Click here

  61. REMOVE INJECTION PIPE SUB-ASSEMBLY RH

    Click here

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

    Click here

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

    Click here

  64. REMOVE VACUUM PUMP ASSEMBLY (w/ Spare Tire)

    Click here

  65. REMOVE CONNECTING WIRE

    Click here

  66. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

    Click here

  67. REMOVE CYLINDER HEAD COVER INSULATOR RH

  68. REMOVE NO. 2 VENTILATION HOSE

    Click here

  69. REMOVE NO. 1 FUEL INJECTOR PROTECTOR

    Click here

  70. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  71. REMOVE FUEL INJECTOR RH

    Click here

  72. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  73. REMOVE NO. 2 FUEL PUMP BRACKET

    Click here

  74. REMOVE CYLINDER HEAD COVER INSULATOR LH

    Click here

  75. REMOVE NO. 3 VENTILATION HOSE

    Click here

  76. REMOVE BREATHER PLUG LH

    Click here

  77. REMOVE NO. 2 FUEL INJECTOR PROTECTOR

    Click here

  78. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  79. REMOVE FUEL INJECTOR LH

    Click here

  80. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  81. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  82. REMOVE NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT


    1. B0019MGE07
      Text in Illustration
      *a Arrow

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

    2. B0019E5

      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 No. 1 chain tensioner assembly, 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 No. 1 chain tensioner assembly, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        B001AVIE02
        Text in Illustration
        *a Stopper Plate - -
    4. B001A3GE01

      Using SST, hold the pump drive shaft gear.

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

    5. Remove the 2 bolts.

    6. B0018GDE08
      Text in Illustration
      *a 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. B0019WFE08
      Text in Illustration
      *a Matchmark

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

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

    9. B0018S1E01

      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 No. 1 timing chain and No. 1 camshaft timing sprocket together.

    12. B0018VF

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

    13. B0019MA

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

    14. B001AAC

      Loosen the 2 union bolts.

    15. B0018LYE02

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

    16. B001B04

      Remove the 2 union bolts and No. 1 camshaft oil feed pipe sub-assembly and No. 2 camshaft oil feed pipe sub-assembly.

    17. B001AES

      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. B0019TM

      Remove the No. 1 camshaft and No. 2 camshaft.

  83. REMOVE NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT


    1. B0018V5E05
      Text in Illustration
      *a Arrow

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

    2. B0019NT

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

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


      1. Push the tensioner slipper away from the No. 2 chain tensioner assembly, 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 No. 2 chain tensioner assembly, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        B0018VXE02
        Text in Illustration
        *a Stopper Plate - -
    4. B0019EDE03

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

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

    5. Remove the 2 bolts.

    6. B0018TVE07
      Text in Illustration
      *a Arrow

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

    7. B0018YNE07
      Text in Illustration
      *a Matchmark

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

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

    9. B0019EDE03

      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 No. 2 timing chain and No. 2 camshaft timing sprocket together.

    11. B0019ZR

      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 No. 4 camshaft so that the bolt is easier to install.

    12. B001ASK

      Loosen the 2 union bolts.

    13. B0018JBE02

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

    14. B0018X4

      Remove the 2 union bolts and No. 3 camshaft oil feed pipe sub-assembly and No. 4 camshaft oil feed pipe sub-assembly.

    15. B00187V

      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. B001AWH

      Remove the No. 3 camshaft and No. 4 camshaft.