Click here

CAMSHAFT (w/o DPF) REMOVAL

Click here
Click here Click here
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.

Click here
  1. Click here

    CHECK INJECTOR COMPENSATION CODE

    Note:

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

    • Fuel injector compensation codes are unique, 30 digit, alphanumeric values printed on the head portion of each fuel injector. If an incorrect fuel 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.


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

      Tip:

      • Each fuel injector 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 fuel injector.

      • When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set. This is to inform you that registration of a fuel injector compensation code(s) is/are required. Manually clear the DTC upon completion of the compensation code registration.


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

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

      3. Turn the tester off and turn the ignition switch off.

      4. Wait for at least 30 seconds.

      5. Turn the ignition switch to ON and turn the tester on.

      6. Clear DTC P1601 stored in the ECM using the tester (Click here).

    2. A0157BSE04

      Register compensation code.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

        Note:

        Do not start the engine.

      3. Turn the tester on.

      4. A0156CME01

        Enter the following menus: Powertrain / Engine / Utility / Injector Compensation.

      5. Press Next.

      6. A015DGLE01

        Press Next again to proceed.

      7. A0155RYE01

        Select "Set Compensation Code".

      8. Press Next.

      9. A015A0R

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

      10. Press Next.

      11. A0156MFE01

        Register compensation code.


        1. Press Input.

        2. A0158O4

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

          Tip:

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

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

      12. A015CD0E01

        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 fuel injector.

        Note:

        If an incorrect fuel 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.

        Tip:

        • 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 compensation code in the ECM.

        Tip:

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

        • If the input 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. A015AQWE01

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

      15. Turn the ignition switch off and then turn the tester off.

      16. Wait for at least 30 seconds.

      17. Turn the ignition switch to ON and then turn the tester on.

      18. Clear DTC P1601 stored in the ECM using the tester (Click here).

  2. Click here

    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. Click here

    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. Click here

    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.

      38 N*m 387 kgf*cm 28 ft.*lbf
  5. Click here

    REMOVE FRONT WHEEL

  6. Click here

    DRAIN CLUTCH FLUID (for Manual Transmission)

  7. Click here

    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. Click here

    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. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

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

  10. Click here

    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.

    Tip:

    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. A015DKUE01

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

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      13 N*m 133 kgf*cm 10 ft.*lbf
  11. Click here

    REMOVE UPPER RADIATOR SUPPORT SEAL


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

  12. Click here

    REMOVE NO. 3 ENGINE ROOM WIRE


    1. Disconnect the 4 wire harness clamps.

    2. A0156P2

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

  13. Click here

    REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)


    1. A015BEI

      Remove the 2 nuts and No. 1 engine cover.

  14. Click here

    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. Click here

    REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

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

  16. Click here

    REMOVE INTAKE AIR CONNECTOR


    1. A015852E04

      w/ Viscous Heater:

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

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

    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. Click here

    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. Click here

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


    1. A015A7A

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

  19. Click here

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


    1. A015C7J

      Remove the nut and No. 3 idler pulley.

  20. Click here

    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. Click here

    REMOVE FRONT FENDER APRON SEAL FRONT RH


    1. A015AN4

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

  22. Click here

    REMOVE FRONT FENDER APRON SEAL REAR RH


    1. A015D4I

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

  23. Click here

    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. Click here

    REMOVE FRONT FENDER APRON SEAL REAR LH


    1. A0155AV

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

  25. Click here

    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. Click here

    REMOVE NO. 1 OIL RESERVOIR BRACKET


    1. A0159Q4

      Remove the 2 bolts and bracket.

  27. Click here

    REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A015BUM

      Disconnect the 2 hoses.

    2. Remove the 3 bolts and radiator reservoir.

  28. Click here

    REMOVE VANE PUMP ASSEMBLY


    1. A0155BZ

      Remove the 2 nuts and vane pump.

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

  29. Click here

    REMOVE OIL COOLER TUBE (for Automatic Transmission)


    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. Click here

    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. Click here

    REMOVE FRONT FENDER MAIN SEAL LH


    1. A0155CK

      Using a clip remover, detach the 3 clips and remove the fender main seal.

  32. Click here

    REMOVE FRONT FENDER MAIN SEAL RH

    Tip:

    Use the same procedure described for the LH side.

  33. Click here

    REMOVE FRONT WIPER ARM LH


    1. Remove the nut, wiper arm and blade.

  34. Click here

    REMOVE FRONT WIPER ARM RH


    1. Remove the nut, wiper arm and blade.

  35. Click here

    REMOVE HOOD TO COWL TOP SEAL


    1. A0155QV

      Using a clip remover, detach the 12 clips, 4 clamps and remove the hood to cowl top seal.

  36. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A015DL2

      Remove the washer hose.

    2. A0157PP

      Remove the 2 clips.

    3. Detach the 17 claws and remove the cowl top ventilator louver sub-assembly.

  37. Click here

    REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    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.

  38. Click here

    REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)


    1. A015E40

      Loosen the No. 1 air hose clamp.

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

    3. A0158C6

      Remove the 3 nuts, bolt and No. 1 cool air inlet.

    4. Remove the gasket from the air tube RH.

  39. Click here

    REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015B0X

      Loosen the No. 2 air hose clamp.

    2. A015A93

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  40. Click here

    REMOVE NO. 1 AIR HOSE


    1. A0158SB

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

  41. Click here

    REMOVE NO. 2 AIR HOSE


    1. A0155DS

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

  42. Click here

    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

      Disconnect the ventilation hose from the cylinder head cover RH.

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

    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.

  43. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  44. Click here

    REMOVE CLUTCH HOSE (for Manual Transmission)


    1. A015C2Z

      Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

      Note:

      • Do not bend or damage the flexible hose tubes.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

    2. Remove the 2 clips.

    3. A0159T9

      Remove the bolt and clutch hose.

  45. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  46. Click here

    REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. A015APM

      Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

      Note:

      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.

    2. A0155T9

      Remove the 2 bolts and tube connector to flexible hose tube.

  47. Click here

    DISCONNECT WATER HOSE SUB-ASSEMBLY

    Table 3. Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater
  48. Click here

    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.

  49. Click here

    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.

  50. Click here

    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.

  51. Click here

    REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015D8F

      Loosen the hose clamp.

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

  52. Click here

    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.

  53. Click here

    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.

  54. Click here

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


    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.

  55. Click here

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


    1. A0155QF

      Remove the bolt and No. 1 idler pulley bracket.

  56. Click here

    REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. A0157IQE01

        Remove the 2 bolts and nut.

        Table 4. 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.

  57. Click here

    DISCONNECT FUEL HOSE


    1. A0159B1E01

      w/ DPF:

      Table 5. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
    2. A0159IIE01

      w/o DPF:

      Table 6. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
  58. Click here

    DISCONNECT ENGINE WIRE


    1. LH Side:


      1. A0155IP

        Disconnect the 4 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 labeled A from the relay block side.

      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. A0158OVE01

        Disconnect the 8 connectors.

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

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

      15. 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. A015A8PE01

        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. A01585NE01

      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. A0155QN

        Disconnect the wire harness from the wire harness clamp holder.

      2. A015DZIE01

        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.

  59. Click here

    REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Note:

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.


    1. A015D15

      Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

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

    3. Remove the union bolt and gasket.

    4. Remove the bolt, nut and No. 2 fuel pipe.

  60. Click here

    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.

  61. Click here

    REMOVE INJECTION PIPE LH


    1. A015B4EE01

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

      Table 7. Text in Illustration
      *A w/ DPF
      *B w/o DPF
    2. A015E5OE01

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

      Table 8. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      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. Click here

    REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01

      Remove the 2 bolts and common rail.

      Table 9. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      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.

  63. Click here

    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.

  64. Click here

    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.

  65. Click here

    REMOVE INJECTION PIPE RH


    1. A0155GHE01

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

      Table 10. Text in Illustration
      *A w/ DPF
      *B w/o DPF
    2. A015B9WE01

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

      Table 11. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      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.

  66. Click here

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


    1. A0159CU

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

  67. Click here

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


    1. A015C5N

      Remove the 3 bolts and idler pulley bracket.

  68. Click here

    REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)


    1. A015COX

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  69. Click here

    REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A015BP2

      w/ Intercooler:

      Disconnect the 2 vacuum hoses.

    2. A0159UD

      Remove the 3 bolts and vacuum transmitting pipe.

  70. Click here

    REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)


    1. A0155AS

      Remove the 3 bolts and vacuum pump.

    2. Remove the 2 O-rings.

  71. Click here

    DISCONNECT NO. 2 VENTILATION HOSE

    Table 12. Text in Illustration
    *A w/ DPF
    *B w/o DPF
  72. Click here

    DISCONNECT NO. 3 VENTILATION HOSE

    Table 13. Text in Illustration
    *A w/ DPF
    *B w/o DPF
  73. Click here

    REMOVE CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)


    1. A015B6D

      Remove the 3 bolts and cylinder head cover silencer.

  74. Click here

    REMOVE CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)


    1. A0158CR

      Remove the 3 bolts and cylinder head cover silencer.

  75. Click here

    REMOVE NOZZLE HOLDER SEAL RH


    1. A015BTY

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tip:

      Tape the screwdriver tip before use.

  76. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A015CK9

      Remove the 18 bolts, cylinder head cover and gasket.

  77. Click here

    REMOVE NOZZLE HOLDER GASKET RH


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tip:

      Tape the screwdriver tip before use.

  78. Click here

    REMOVE OIL SEPARATOR ASSEMBLY


    1. A0157GO

      Remove the 3 bolts, oil separator and gasket.

  79. Click here

    REMOVE NOZZLE HOLDER SEAL LH


    1. A0158R5

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tip:

      Tape the screwdriver tip before use.

  80. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A015DOO

      Remove the 17 bolts, cylinder head cover and gasket.

  81. Click here

    REMOVE NOZZLE HOLDER GASKET LH


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tip:

      Tape the screwdriver tip before use.

  82. Click here

    REMOVE FUEL INJECTOR RH


    1. A015DUS

      Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

      Table 14. Text in Illustration
      A015CC1 Union Bolt
      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.

    2. A01575P

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

      Tip:

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

    3. Remove the O-ring from each injector.

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

  83. Click here

    REMOVE FUEL INJECTOR LH


    1. A015CZW

      Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

      Table 15. Text in Illustration
      A015CC1 Union Bolt
      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.

    2. A015AEN

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

      Tip:

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

    3. Remove the O-ring from each injector.

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

  84. Click here

    REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. A015AOXE01

      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. A0155CQE01

        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.

    4. A015BGKE01

      Using SST, hold the pump drive shaft gear.

      09960-10010 09962-01000 09963-01000

    5. Remove the 2 bolts.

    6. A0157T2E02

      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. A0156PIE02

      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.

      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.

      Tip:

      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.

      8.0 N*m 82 kgf*cm 71 in.*lbf
      Note:

      Do not drop the bolt into the engine.

      Tip:

      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.

      Tip:

      Be sure to arrange the removed parts for each installation position separately.

    18. A0157MH

      Remove the No. 1 and No. 2 camshafts.

  85. Click here

    REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. A0159XM

      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. A0159ZPE01

        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.

    4. A0155ILE03

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

      09960-10010 09962-01000 09963-01000

    5. Remove the 2 bolts.

    6. A015CD3E02

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

    7. A015D4FE02

      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.

      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.

      Tip:

      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.

      8.0 N*m 82 kgf*cm 71 in.*lbf
      Note:

      Do not drop the bolt into the chain cover.

      Tip:

      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.

      Tip:

      Be sure to arrange the removed parts for each installation position separately.

    16. A015833

      Remove the No. 3 and No. 4 camshafts.