CAMSHAFT (w/ DPF) REMOVAL

CAUTION:

When replacing an injector (including interchanging injectors between cylinders), common rail, 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.


  1. CHECK INJECTOR COMPENSATION CODE

    A0159NUE05

    Note


    • When an injector assembly is replaced, the new injector compensation code must be input into the ECM. When the ECM is replaced, all of the existing injector compensation codes must be input into the new ECM.

    • Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each injector assembly. If an incorrect injector compensation code is input into the ECM, the engine assembly may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

    • When an injector compensation code is input into the ECM, the pilot quantity learning values stored in the ECM are initialized. Also, DTC P062F is stored when the pilot quantity learning values are initialized.

    Text in Illustration
    *1 Injector Compensation Code
    *a Example

    1. After replacing injector assemblies with new one(s), input injector compensation code(s) of the injector assemblies into the ECM as follows:

      Tech Tips


      • Each injector assembly has different fuel injection characteristics. In order to optimize the fuel injections, the ECM uses the compensation codes to balance the different fuel injections between each injector assembly.

      • When only one or more injector assemblies are replaced, input the injector compensation code(s), perform pilot quantity learning, and then clear the DTCs.

      • When the engine switch is turned on (IG) after replacing the ECM, DTC P062F is stored. This indicates that the injector compensation code(s) need to be registered. Manually clear the DTC upon completion of pilot quantity learning.


      1. Input the compensation code(s), which is/are imprinted on the head portion(s) of the new injector assemblies, into the GTS.

      2. Input the new injector compensation code(s) into the ECM using the GTS.

      3. Turn the GTS off and turn the engine switch off.

      4. Wait for at least 30 seconds.

      5. Turn the engine switch on (IG) and turn the GTS on.

      6. Perform pilot quantity learning.

      7. Clear DTC P062F stored in the ECM using the GTS Click here.

        Note

        If the DTCs are cleared without performing pilot quantity learning, DTC P062F is stored immediately after clearing DTCs.

    2. Register compensation codes.

      A015AIOE04

      1. Connect the GTS to the DLC3.

      2. Turn the engine switch on (IG).

        Note

        Do not start the engine.

      3. Turn the GTS on.

      4. A015BL1

        Enter the following menus: Engine and ECT / Utility / Injector Compensation.

      5. Press Next.

      6. A015BOM

        Press Next again to proceed.

      7. A015C4R

        Select "Set Compensation Code".

      8. Press Next.

      9. A0159FQ

        Select the number of the cylinder corresponding to the injector compensation code that you want to register.

      10. Press Next.

      11. A015CV0

        Register compensation code.


        1. Press Input.

        2. A0158O4

          Manually input the cylinder compensation code using the keyboard on the GTS screen. The code is a 30-digit, alphanumeric value printed on the injector head portion.

          Tech Tips

          Each injector compensation code is unique. The compensation code for each selected cylinder must be input into the GTS correctly.

        3. Confirm that the compensation code for the selected cylinder is correct, and then press OK.

      12. A015C7A

        Check that the compensation code displayed on the screen is correct by comparing it with the 30-digit alphanumeric value on the head portion of the injector assembly.

        Note

        If an incorrect injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

        Tech Tips


        • If a wrong compensation code is input or read, return to the Input Value screen by pressing Input.

        • The saving process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and repeat this operation.

      13. Press Next to register the injector compensation code in the ECM.

        Tech Tips


        • If the registration process fails, the injector compensation code may be incorrect. Check the injector compensation code again.

        • If the input injector compensation code fails to register even though it is input correctly, there may be a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and restart this operation.

      14. A0158CJ

        If you want to continue with other compensation code registrations, press Next. To finish the registration, press Exit.

      15. Turn the GTS off and turn the engine switch off.

      16. Wait for at least 30 seconds.

      17. Turn the engine switch on (IG), and then turn the GTS on.

      18. Perform pilot quantity learning.

      19. Clear DTC P062F stored in the ECM using the GTS Click here.

        Note

        If the DTCs are cleared without performing pilot quantity learning, DTC P062F is stored immediately after clearing DTCs.

  2. 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.

  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.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. DRAIN ENGINE OIL


    1. A0158YG

      Remove the 2 bolts and No. 2 engine under cover seal from the No. 2 engine under cover.

    2. Remove the oil filler cap.

    3. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  6. REMOVE FRONT WHEEL

  7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. A015DL0

      Remove the 3 bolts and screw.

    2. Loosen the clip and remove the front fender splash shield LH.

  8. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Remove the 3 bolts and 2 screws.

    2. Loosen the clip and remove the front fender splash shield RH.

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


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  10. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Collect the coolant in a container and dispose of it according to the regulations in your area.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator reservoir cap to drain the coolant in the radiator.

    3. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

      A015DKUE01

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  11. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 7 clips and upper radiator support seal.

  12. REMOVE NO. 3 ENGINE ROOM WIRE


    1. Disconnect the 4 wire harness clamps.

    2. Remove the 2 nuts and No. 3 engine room wire.

      A0156P2

  13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A015BEI

      Remove the 2 nuts and No. 1 engine cover.

  14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  15. REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

      Loosen the hose clamp and remove the No. 1 air cleaner hose.

  16. REMOVE INTAKE AIR CONNECTOR


    1. A015852E04
      Text in Illustration
      *A w/ Viscous Heater

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

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

    4. A015DJJ

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

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


    1. A0155TJ

      Loosen the lock nut and turn the bolt counterclockwise.

    2. Remove the V-ribbed belt.

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


    1. A015A7A

      Remove the bolt, cover, No. 1 idler pulley and collar.

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


    1. A015C7J

      Remove the nut and No. 3 idler pulley.

  20. REMOVE V-RIBBED BELT


    1. A015CL0

      Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

  21. REMOVE FRONT FENDER APRON SEAL FRONT RH


    1. A015AN4

      Remove the 3 clips and front fender apron seal front RH.

  22. REMOVE FRONT FENDER APRON SEAL REAR RH


    1. A015D4I

      Remove the 4 clips and front fender apron seal rear RH.

  23. REMOVE FRONT FENDER APRON SEAL FRONT LH


    1. A015BDJ

      w/o KDSS:

      Remove the 4 clips and front fender apron seal front LH.

    2. A015CC0

      w/ KDSS:

      Remove the 3 clips and front fender apron seal front LH.

  24. REMOVE FRONT FENDER APRON SEAL REAR LH


    1. A0155AV

      Remove the 4 clips and front fender apron seal rear LH.

  25. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A0155N2

      Insert a screwdriver between the reservoir and oil reservoir bracket, push the claw, and then disconnect the reservoir by pulling it upwards.

  26. REMOVE NO. 1 OIL RESERVOIR BRACKET


    1. A0159Q4

      Remove the 2 bolts and bracket.

  27. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A015BUM

      Disconnect the 2 hoses.

    2. Remove the 3 bolts and radiator reservoir.

  28. REMOVE VANE PUMP ASSEMBLY


    1. A0155BZ

      Remove the 2 nuts and vane pump.

    2. Remove the O-ring from the vane pump.

  29. REMOVE OIL COOLER TUBE


    1. A01572W

      Disconnect the inlet and outlet No. 1 oil cooler hose.

    2. A015CST

      Disconnect the inlet No. 2 and No. 3 oil cooler hoses.

    3. A015BIC

      Disconnect the inlet No. 4 oil cooler hose.

    4. A01566A

      Remove the 2 bolts and transmission oil cooler tube.

  30. REMOVE FAN SHROUD WITH FAN


    1. A015CLN

      Loosen the 4 nuts holding the fluid coupling fan.

    2. A0159DG

      Remove the 2 bolts holding the fan shroud.

    3. A015B5D

      Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid coupling fan.

  31. REMOVE INTERCOOLER ASSEMBLY


    1. A0158Z5

      Loosen the No. 1 air hose clamp.

    2. A015BZV

      Loosen the No. 2 air hose clamp.

    3. A0155JY

      Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    4. A015DCM

      Remove the 6 nuts, 2 bolts and intercooler.

    5. Remove the 2 gaskets from the air tube LH and RH.

  32. REMOVE NO. 1 AIR HOSE


    1. A0158SB

      Loosen the hose clamp and remove the No. 1 air hose.

  33. REMOVE NO. 2 AIR HOSE


    1. A0155DS

      Loosen the hose clamp and remove the No. 2 air hose.

  34. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156LC

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. A015C0GE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the ventilation hose from the cylinder head cover RH.

    3. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

    4. Remove the O-ring from the No. 2 engine oil level dipstick guide.

  35. REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  36. REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  37. DISCONNECT WATER HOSE SUB-ASSEMBLY

    A015CADE02
    Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater

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


    1. A015DM6

      Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

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


    1. A0158HY

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

  40. REMOVE NO. 3 AIR TUBE


    1. A0159U8

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. A0155HD

      Remove the bolt and disconnect the wire harness bracket.

    4. A01572L

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  41. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015D8F

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  42. REMOVE NO. 4 AIR TUBE


    1. A015A8F

      Remove the bolt and disconnect the suction hose.

    2. A015577

      Loosen the hose clamp and remove the bolt and No. 4 air tube.

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


    1. A015AEL

      Disconnect the ventilation hose from the oil separator.

    2. Loosen the hose clamp.

    3. Remove the bolt and No. 2 air cleaner pipe.

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

    A01560B

    1. Disconnect the connector and detach the clamp.

    2. Using pliers, grip the claws of the clips and slide the 2 clips.

    3. Disconnect the 2 heater hoses.

    4. Remove the 2 bolts and heater assembly.

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


    1. A0155QF

      Remove the bolt and No. 1 idler pulley bracket.

  46. REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. Remove the 2 bolts and nut.

        A0157IQE01
        Text in Illustration
        *A w/ DPF *B w/o DPF

      2. w/ DPF:

        Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

      3. w/o DPF:

        Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

    2. w/o EGR System:


      1. A0157AC

        Remove the 2 bolts and nut.

      2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

  47. DISCONNECT FUEL HOSE


    1. A0159B1E01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/ DPF:

    2. A0159IIE01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/o DPF:

  48. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. A015AEA

        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. A015BB9E01

        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. A015D5V

        Disconnect the 4 connectors.

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

      10. A015AFR

        Disconnect the 2 connectors.

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

      12. A015AT7E01

        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. A015AXC

        Disconnect the 4 connectors.

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

      3. A015BN3E01

        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. A01585NE01

      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. A015B6W

        Disconnect the wire harness from the wire harness clamp holder.

      2. Remove the bolt and wire harness clamp holder.

      3. A015DZIE01

        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

    Note

    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


    1. w/ EGR System:


      1. A0157JU

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.

      3. Remove the No. 6 injection pipe.

    2. w/o EGR System:


      1. A0159AO

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the nut and No. 2 injection pipe clamp.

      3. Remove the bolt and No. 6 injection pipe.

  50. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01576L

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

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


    1. A015AL5

      Disconnect the 2 vacuum hoses.

    2. A0159QH

      Remove the 3 bolts and vacuum transmitting pipe.

  52. REMOVE CYLINDER HEAD COVER SILENCER LH


    1. A015AO1

      Remove the 4 bolts and cylinder head cover silencer.

  53. REMOVE NO. 4 NOZZLE LEAKAGE PIPE


    1. A01571T

      Disconnect the fuel hose.

    2. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

  54. REMOVE INJECTION PIPE LH


    1. A015B4EE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015E5OE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  55. REMOVE NO. 2 FUEL PIPE


    1. A015CIM

      Remove the No. 4 fuel hose.

    2. Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

  56. REMOVE NO. 5 NOZZLE LEAKAGE PIPE


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. A015E4L

        Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

    2. A0156LG

      w/o DPF:

      Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

  57. REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note


      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

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


    1. w/ DPF:


      1. A015D39

        Remove the bolt and No. 2 injection pipe clamp.

      2. Disconnect the fuel hose.

      3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

    2. w/o DPF:


      1. A01588A

        Disconnect the 2 hoses from the fuel pipe.

      2. Remove the bolt and fuel filter to injection pump fuel pipe.

  59. DISCONNECT NO. 2 ENGINE WIRE


    1. A0156MM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  60. REMOVE CYLINDER HEAD COVER SILENCER RH


    1. A015AD8

      Remove the 4 bolts and cylinder head cover silencer.

  61. REMOVE INJECTION PIPE RH


    1. A0155GHE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015B9WE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

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


    1. A0159CU

      Remove the bolt, cover, No. 2 idler pulley and collar.

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


    1. A015C5N

      Remove the 3 bolts and idler pulley bracket.

  64. REMOVE VACUUM PUMP ASSEMBLY


    1. A0155AS

      Remove the 3 bolts and vacuum pump.

    2. Remove the 2 O-rings.

  65. REMOVE CONNECTING WIRE


    1. A0158N3

      Detach the 2 clamps and remove the connecting wire.

  66. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A0155NQ

      Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

  67. REMOVE CYLINDER HEAD COVER INSULATOR RH

  68. REMOVE NO. 2 VENTILATION HOSE

    A0159XJE01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  69. REMOVE NO. 1 FUEL INJECTOR PROTECTOR


    1. A0156CK

      Remove the bolt and No. 1 fuel injector protector.

  70. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A0156JO

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 No. 2 Check Valve
      A0158FK Union Bolt

    2. Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

    3. Remove the union bolt and No. 1 nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  71. REMOVE FUEL INJECTOR RH


    1. A015611

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.

  72. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A015CFS

      Remove the 19 bolts, 4 nozzle holder clamp seats and cylinder head cover RH.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nozzle Holder Clamp Seat

    2. Remove the cylinder head cover gasket RH and No. 3 cylinder head cover gasket from the cylinder head cover RH.

  73. REMOVE NO. 2 FUEL PUMP BRACKET


    1. A015APQ

      Remove the bolt and No. 2 fuel pump bracket.

  74. REMOVE CYLINDER HEAD COVER INSULATOR LH

    A015B24

  75. REMOVE NO. 3 VENTILATION HOSE

    A015CQ4E01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  76. REMOVE BREATHER PLUG LH


    1. A01562TE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the hose.

    2. w/o DPF:

      Detach the clamp.

    3. Remove the breather plug LH.

  77. REMOVE NO. 2 FUEL INJECTOR PROTECTOR


    1. A0156K1

      Detach the hose clamp.

    2. Remove the bolt and No. 2 fuel injector protector.

  78. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A015BOU

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Bolt

    2. Remove the 2 bolts and No. 2 nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  79. REMOVE FUEL INJECTOR LH


    1. A0157BA

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    2. Remove the O-ring from each injector.

    3. Remove the 4 injection nozzle seats from the cylinder head.

  80. REMOVE OIL SEPARATOR ASSEMBLY


    1. A0157GO

      Remove the 3 bolts, oil separator and gasket.

  81. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A015D3Z

      Remove the 18 bolts, 4 nozzle holder clamp seats and cylinder head cover LH.

      Text in Illustration
      A015DIT Bolt
      A015CC1 Nozzle Holder Clamp Seat

    2. Remove the cylinder head cover gasket LH and No. 4 cylinder head cover gasket from the cylinder head cover LH.

  82. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. A015AOXE02
      Text in Illustration
      *1 Arrow

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

    2. A015CZD

      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 tensioner, 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 tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        A0155CQE02
        Text in Illustration
        *1 Stopper Plate - -
    4. A015BGKE01

      Using SST, hold the pump drive shaft gear.

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

    5. Remove the 2 bolts.

    6. A0157T2E03
      Text in Illustration
      *1 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. A0156PIE03
      Text in Illustration
      *1 Matchmark

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

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

    9. A015AGJE01

      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 sprocket and chain together.

    12. A0155OX

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

    13. A015784

      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 camshaft so that the bolt is easier to install.

    14. A015DV6

      Loosen the 2 union bolts.

    15. A015A5AE01

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

    16. A0157Z4

      Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

    17. A015AF3

      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. A0157MH

      Remove the No. 1 and No. 2 camshafts.

  83. REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. A0159XME02
      Text in Illustration
      *1 Arrow

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

    2. A015BBY

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

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


      1. Push the tensioner slipper away from the tensioner, 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 tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

        Note

        Do not drop the hexagon wrench into the engine.

        A0159ZPE02
        Text in Illustration
        *1 Stopper Plate - -
    4. A0155ILE03

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

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

    5. Remove the 2 bolts.

    6. A015CD3E03
      Text in Illustration
      *1 Arrow

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

    7. A015D4FE03
      Text in Illustration
      *1 Matchmark

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

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

    9. A0155ILE03

      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 sprocket and chain together.

    11. A015E5P

      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 camshaft so that the bolt is easier to install.

    12. A0155KQ

      Loosen the 2 union bolts.

    13. A015C4IE01

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

    14. A0158FA

      Remove the 2 union bolts and No. 3 and No. 4 oil feed pipes.

    15. A015DEI

      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. A015833

      Remove the No. 3 and No. 4 camshafts.