РАСПРЕДВАЛ СНЯТИЕ

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 dirt contamination.

    Cover the generator assembly with suitable materials.

    Failure to comply with this procedure may result in a generator assembly malfunction.

  • A01IPPME01

    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

  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 RADIATOR ASSEMBLY

    Click here

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  5. REMOVE ENGINE COVER

    A01IRTM

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


    1. A01IT1KE01
      Text in Illustration
      *1 Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

    5. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  7. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IN4S

      Remove the 3 bolts and air cleaner case sub-assembly.

  9. DISCONNECT ENGINE WIRE


    1. A01IO8C

      Detach the 2 clamps and disconnect the glow plug controller assembly harness connector.

    2. A01IUSI

      Disconnect the EGR gas temperature sensor connector.

    3. Detach the 6 clamps and disconnect the fuel quantity control valve connector.

    4. A01IT7Z

      Disconnect the swirl control valve connector.

    5. Disconnect the fuel pressure sensor connector.

    6. Disconnect the engine coolant temperature sensor connector.

    7. Disconnect the generator assembly connector.

    8. Disconnect the camshaft position sensor connector.

    9. Disconnect the turbo pressure sensor assembly connector.

    10. Disconnect the 2 glow plug controller assembly connectors.

    11. Detach the 2 clamps.

    12. Using a T25 "TORX" socket wrench, remove the screw and disconnect the engine wire.

  10. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IRBY

      Detach the clamp and disconnect the fuel feed pipe sub-assembly from the engine oil level dipstick guide.

    3. Using a T25 "TORX" socket wrench, remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring from the engine oil level dipstick guide.

  11. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY


    1. A01IR4WE01
      Text in Illustration
      *1 No. 1 Vacuum Pipe

      Disconnect the No. 2 vacuum hose assembly from the No. 1 vacuum pipe.


      1. Check that there is no damage or foreign matter on the part of the No. 1 vacuum pipe that contacts the No. 2 vacuum hose assembly connector.

      2. A01ISEDE01
        Text in Illustration
        *1 Retainer
        A01ISM9 Pinch
        A01ISER Pull Out

        If the No. 2 vacuum hose assembly connector and No. 1 vacuum pipe are stuck together, hold the No. 1 vacuum pipe by hand and push and pull on the No. 2 vacuum hose assembly connector.

        Note


        • Check for any dirt and foreign matter contamination in the No. 1 vacuum pipe and around the No. 2 vacuum hose assembly connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Do not use any tools to separate the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Check for any dirt and foreign matter on the No. 1 vacuum pipe seal surface. Clean if necessary.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the No. 2 vacuum hose assembly.

        • If the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector are stuck together, pinch the No. 2 vacuum hose assembly connector between your fingers and turn it carefully to free it. Then disconnect the No. 2 vacuum hose assembly.

      3. Check for dirt or mud on the No. 1 vacuum pipe seal surface of the disconnected No. 1 vacuum pipe. Clean if necessary.

      4. To protect the disconnected No. 1 vacuum pipe and No. 2 vacuum hose assembly connector from damage and contamination, cover them with a plastic bag and tape.

  12. REMOVE NO. 1 VACUUM PIPE


    1. A01IPF5

      Disconnect the vacuum hose.

    2. Using an E7 "TORX" socket wrench, remove the bolt and No. 1 vacuum pipe from the cylinder block sub-assembly.

    3. Remove the O-ring from the No. 1 vacuum pipe.

  13. REMOVE INTAKE MANIFOLD


    1. A01IQ8RE01

      Remove the bolt labeled B and loosen the 6 bolts labeled A in the order shown in the illustration, and then remove the intake manifold.

      Text in Illustration
      A01ISM9 Bolt A
      A01ISER Bolt B

      Tech Tips

      The bolts labeled A in the illustration cannot be removed from the intake manifold.

    2. A01IS46

      Remove the 4 gaskets from the intake manifold.

    3. Remove the gasket from the No. 2 EGR pipe sub-assembly.

  14. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY

    A01INZYE01

    Note

    Reset SST in a timely manner to prevent bending of pressure lines.


    1. Using SST, loosen the 4 union nuts at the common rail assembly end of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST
      PZ4TB-04959-10

    2. Using SST, loosen the 4 union nuts at the 4 injector assembly ends of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST
      PZ4TB-04959-10

    3. Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

  16. REMOVE COMMON RAIL ASSEMBLY


    1. A01IUBA

      Disconnect the fuel pressure sensor connector.

    2. A01ITAB

      Disconnect the pressure discharge valve connector.

    3. A01ISCXE01
      Text in Illustration
      *a Push

      Push at the location shown in the illustration and disconnect the fuel return tube.

    4. A01IS4P

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 2 common rail assembly brackets.

    5. Remove the common rail assembly from the cylinder head cover sub-assembly.

  17. REMOVE CAMSHAFT POSITION SENSOR


    1. A01IUP4

      Disconnect the camshaft position sensor connector.

    2. Using an E6 "TORX" socket wrench, remove the bolt and camshaft position sensor.

  18. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01IQZ7

      Disconnect the connector and detach the 2 clamps to disconnect the wire harness Click here.

    2. A01IOW8E01
      Text in Illustration
      *1 Sealing Ring
      *2 Leakage Line
      *3 Clip
      *a Pull Up

      Pull up the 4 clips and disconnect the nozzle leakage pipe assembly from the 4 injector assemblies as shown in the illustration.

      Note

      If a sealing ring is damaged, the entire leakage line of a cylinder group must be replaced.

    3. Remove the 4 sealing rings from the nozzle leakage pipe assembly.

  19. REMOVE INJECTOR ASSEMBLY


    1. A01ISRF

      Disconnect the 4 injector assembly connectors.

    2. A01IRX9

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 4 centering rings.

    3. Remove the 4 clamping claws from the 4 injector assemblies.

    4. A01ITN6E01

      Remove the 4 injector assemblies from the cylinder head cover sub-assembly.


      1. Pull out the injector assembly with light rotational movements.

        SST
        PZ4TB-04942-79

        Tech Tips


        • If an injector assembly is stuck tight, mount SST (rod) to the pressure line connection.

        • Move injector assembly with SST (rod) only by a few degrees.

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01ISTL

      Remove the plug from the cylinder block.

    2. A01IQM6E01

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

      SST(A)
      PZ4TB-04951-26
    3. A01IT6AE02
      Text in Illustration
      *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.

  21. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  22. REMOVE VACUUM CONTROL VALVE BRACKET


    1. A01IQL8

      Disconnect the exhaust gas temperature sensor connector.

    2. Detach the wire harness clamp.

    3. A01ISPFE01
      Text in Illustration
      *a Air Fuel Ratio Sensor Connector
      *b Exhaust Gas Temperature Sensor Connector
      *c Clamp

      Disconnect the exhaust gas temperature sensor connector.

    4. Disconnect the air fuel ratio sensor connector.

    5. Raise the air fuel ratio sensor connector from the vacuum control valve bracket.

    6. Move the clamp as shown in the illustration, and disconnect the air fuel ratio sensor and exhaust gas temperature sensor.

      Note

      Disconnect the sensors while opening the clamp.

    7. Detach the air fuel ratio sensor clamp from the vacuum control valve bracket.

    8. A01IUEI

      Using a T20 "TORX" socket wrench, remove the 3 screws and disconnect the vacuum control valve bracket.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01ISMT

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

      Tech Tips

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

    2. A01INR9

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

  24. HOLDING CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01IQV1E02
      Text in Illustration
      *a Mark E (Intake Side)
      *b Mark A (Exhaust Side)

      Check that the camshaft and No. 2 camshaft on the camshaft housing sub-assembly as shown in the illustration so that mark E and mark A face upward.

      Note

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

    2. A01IU2EE01
      Text in Illustration
      *a Timing Mark

      Check the camshaft and No. 2 camshaft timing marks.

    3. A01IUCME01
      Text in Illustration
      *a No Clearance

      Set SST and 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.

  25. REMOVE NO. 1 TURBO INSULATOR


    1. A01IQ49

      Remove the 3 bolts, nut and No. 1 turbo insulator.

  26. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01IQ35

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

  27. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01ITHE

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

  28. REMOVE NO. 2 ENGINE HANGER


    1. A01IQFT

      Remove the 2 bolts and No. 2 engine hanger from the cylinder head sub-assembly.

  29. REMOVE NO. 2 TIMING CHAIN GUIDE


    1. A01INY5

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

  30. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01IPNX

      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. A01IQUP

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

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

    4. A01IO4HE01

      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.

  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01ITFSE01

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

    2. A01IQRC

      Remove the 4 gaskets.

  32. 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.

  33. 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.