CAMSHAFT REMOVAL

PROCEDURE


  1. PRECAUTION

    Note


    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A01T959N01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST
      PZ4TB-04941-79

    • 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 RADIATOR ASSEMBLY

    Click here

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  5. REMOVE ENGINE COVER

    Click here

  6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  8. DISCONNECT ENGINE WIRE

    Click here

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  10. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

    Click here

  11. REMOVE NO. 1 VACUUM PIPE

    Click here

  12. REMOVE INTAKE MANIFOLD

    Click here

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  14. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE COMMON RAIL ASSEMBLY

    Click here

  16. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  17. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  18. REMOVE INJECTOR ASSEMBLY

    Click here

  19. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. A01T8IC

      Remove the plug from the cylinder block.

    2. A01TCO9N01

      Set SST (A) to the plug hole of the cylinder block.

      SST (A)
      PZ4TB-04951-26
    3. A01TCLKC01
      *1 Flywheel with Damper Assembly
      *a Groove

      Using SST (B), turn the crankshaft pulley clockwise until SST (A) fits into the groove of the flywheel with damper assembly.

      SST (B)
      PZ4TB-04933-80

    4. Using SST (A), hold the flywheel with damper assembly.

      SST (A)
      PZ4TB-04951-26

    5. Remove SST.

    6. Install the plug to the cylinder block.

  20. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    Click here

  21. REMOVE VACUUM CONTROL VALVE BRACKET

    Click here

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01T99F

      Using an E10 "TORX" socket wrench, loosen the 17 bolts and remove the cylinder head cover sub-assembly.

      Tech Tips

      The bolts cannot be removed from the cylinder head cover sub-assembly.

    2. A01TAE6

      Remove the 5 gaskets from the cylinder head cover sub-assembly.

  23. SECURE CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01TBMMC01
      *a Mark (E) (Intake Side)
      *b Mark (A) (Exhaust Side)

      Check that the mark (E) and mark (A) of the camshaft and No. 2 camshaft are facing upward.

      Note

      If the marks of the camshaft and No. 2 camshaft are not aligned as shown in the illustration, set No. 1 cylinder to TDC again.

    2. A01T8UGC01
      *a Timing Mark

      Check the camshaft and No. 2 camshaft timing marks.

    3. A01TDJAC01
      *a No Clearance

      Set SST to secure the camshaft and No. 2 camshaft.

      SST
      PZ4TB-04961-12

      Note

      Make sure there is no clearance between SST and the camshaft housing sub-assembly.

  24. REMOVE NO. 1 TURBO INSULATOR

    Click here

  25. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  26. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01T9OF

      Using a 24 mm socket wrench, remove the No. 2 chain tensioner assembly.

  27. REMOVE NO. 2 ENGINE HANGER

    Click here

  28. REMOVE NO. 2 TIMING CHAIN GUIDE


    1. A01TDRA

      Using a T45 "TORX" socket wrench, remove the bolt and No. 2 timing chain guide.

  29. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01T99X

      Using an E10 "TORX" socket wrench, remove the 3 bolts and the camshaft timing sprocket.

      Note

      Do not drop the No. 2 chain sub-assembly into the gap between the cylinder block and timing chain cover plate.

    2. A01T9VG

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

    3. Remove SST from the camshaft and No. 2 camshaft.

    4. A01TBT0N01

      Using an E8 "TORX" socket wrench, uniformly loosen the 20 bolts 180° in several steps in the sequence shown in the illustration.

    5. Uniformly loosen the 20 bolts further in several steps in the sequence shown in the illustration and remove the bolts.

    6. Remove the 5 intake camshaft bearing caps and 5 exhaust camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    7. Remove the camshaft and No. 2 camshaft.

  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01TCCGN01

      Using an E10 "TORX" socket wrench, remove the 14 bolts and camshaft housing sub-assembly.

    2. A01TB61

      Remove the 4 gaskets.

  31. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.