CAMSHAFT(w/o 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.

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. DRAIN ENGINE OIL

    Click here

  5. REMOVE FRONT WHEEL

  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

    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

    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

    Click here

  37. REMOVE NO. 1 AIR HOSE

    Click here

  38. REMOVE NO. 2 AIR HOSE

    Click here

  39. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  40. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  41. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  42. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  45. REMOVE NO. 3 AIR TUBE

    Click here

  46. REMOVE AIR CLEANER PIPE

    Click here

  47. REMOVE NO. 4 AIR TUBE

    Click here

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

    Click here

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

    Click here

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

    Click here

  51. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  52. DISCONNECT FUEL HOSE

    Click here

  53. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B0019Z7

        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. B0019FEE02

        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. 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. B001A6FE02

        Disconnect the 8 connectors.

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

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

      15. 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. B001AGUE02

        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. B00183ZE01

      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. B00197B

        Disconnect the wire harness from the wire harness clamp holder.

      2. B0018E3E02

        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.

  54. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  55. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  56. REMOVE INJECTION PIPE SUB-ASSEMBLY LH

    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 INJECTION PIPE SUB-ASSEMBLY RH

    Click here

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

    Click here

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

    Click here

  63. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

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

    Click here

  65. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  66. DISCONNECT NO. 2 VENTILATION HOSE

    Click here

  67. DISCONNECT NO. 3 VENTILATION HOSE

    Click here

  68. REMOVE CYLINDER HEAD COVER SILENCER RH

    Click here

  69. REMOVE CYLINDER HEAD COVER SILENCER LH

    Click here

  70. REMOVE NOZZLE HOLDER SEAL RH

    Click here

  71. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  72. REMOVE NOZZLE HOLDER GASKET RH

    Click here

  73. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  74. REMOVE NOZZLE HOLDER SEAL LH

    Click here

  75. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  76. REMOVE NOZZLE HOLDER GASKET LH

    Click here

  77. REMOVE FUEL INJECTOR RH

    Click here

  78. REMOVE FUEL INJECTOR LH

    Click here

  79. 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 assembly 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.

        B0018OOE02
        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. B0019WFE05
      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.

  80. 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.