CAMSHAFT(w/o EGR Cooler) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the camshaft removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

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  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

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CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B0068EY

Note


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

  • 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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  3. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD)

  4. DRAIN ENGINE COOLANT

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  5. REMOVE FRONT BUMPER

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  6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  7. REMOVE NO. 1 RADIATOR AIR GUIDE

    Click here

  8. REMOVE NO. 4 AIR HOSE

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  9. REMOVE NO. 2 AIR TUBE

    Click here

  10. REMOVE NO. 1 RADIATOR HOSE

    Click here

  11. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  12. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  13. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    Click here

  14. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

    Click here

  15. DISCONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)

    Click here

  16. REMOVE FAN SHROUD

    Click here

  17. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  18. REMOVE RADIATOR ASSEMBLY

    Click here

  19. REMOVE INTERCOOLER AIR TUBE

    Click here

  20. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  21. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  22. REMOVE GAS FILTER

    Click here

  23. REMOVE TURBO PRESSURE SENSOR

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  24. REMOVE NO. 2 HOSE TO HOSE TUBE

    Click here

  25. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  26. DISCONNECT FUEL FILTER ASSEMBLY

    Click here

  27. DISCONNECT ENGINE WIRE

    Click here

  28. REMOVE EGR VALVE BRACKET

    Click here

  29. REMOVE NO. 2 EGR PIPE

    Click here

  30. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  31. REMOVE EGR VALVE ADAPTER

    Click here

  32. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  33. REMOVE HARNESS BRACKET

    Click here

  34. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

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

    Click here

  36. REMOVE INJECTOR ASSEMBLY

    Click here

  37. REMOVE NOZZLE HOLDER GASKET

    Click here

  38. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  39. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  40. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0027BDC01
      *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.

  41. REMOVE NO. 3 CAMSHAFT BEARING CAP


    1. B0026OP

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

  42. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  43. REMOVE CAMSHAFT OIL SEAL RETAINER

    Click here

  44. REMOVE TIMING CHAIN GUIDE


    1. B0026LY

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

  45. REMOVE CAMSHAFT


    1. B0027ZL

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

    2. B0024ILC01
      *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. B0028MEC01
      *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.

      Note

      Be careful not to damage the cylinder head sub-assembly with the wrench.

    4. B0025L3N01

      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.

    5. B0027E9

      Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.

    6. Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.

    7. B002746

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

    8. B0024K6

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

    9. B0027UM

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

    10. B0028R5

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

    11. B00286N

      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.