CAMSHAFT (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

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


    1. Remove the 4 bolts and No. 1 engine under cover.

  4. 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.


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A00JWDE

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A00JTSGE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  5. REMOVE FRONT WHEEL LH

  6. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and front fender apron seal LH.

  7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  8. DISCONNECT NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A00K026E01
      Text in Illustration
      *1 No. 1 Engine Cover Hook
      *2 No. 3 Engine Cover Bracket

      Remove the 2 nuts.

    2. Detach the 2 No. 1 engine cover hooks from the No. 3 engine cover bracket and remove the No. 1 engine cover.

  9. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  10. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A00JWE7

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  11. DISCONNECT INTERCOOLER AIR HOSE


    1. A00JWYI

      Loosen the hose clamp and disconnect the intercooler air hose.

  12. REMOVE NO. 1 INTAKE PIPE


    1. A00JUXG

      Disconnect the 2 connectors from the intake air temperature sensor and throttle position sensor.

    2. Detach the 2 wire harness clamps.

    3. A00K12F

      Loosen the 2 hose clamps of the No. 1 air hose.

    4. Remove the 2 bolts and No. 1 intake pipe.

  13. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A00JV51

      Disconnect the throttle control motor connector.

    2. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  14. REMOVE INJECTOR DRIVER


    1. A00O87J

      Disconnect the 4 connectors.

    2. Remove the 2 bolts and injector driver assembly.

  15. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A00JZHZ

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  16. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A00K07S

      Disconnect the 3 vacuum switching valve connectors.

    2. A00JXQ8

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00JWWJ

      Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.

    4. A00K0R0

      Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    5. A00JZPM

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A00JY27

      Remove the bolt and No. 2 injection pipe clamp.

    2. A00JTVIE01
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  18. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

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


    1. A00JX3O

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A00JZI1

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

    3. A00JZZPE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  19. DISCONNECT HEATER WATER PIPE SUB-ASSEMBLY


    1. A00JY3K

      Detach the water by-pass hose clamp.

    2. Remove the bolt and disconnect the heater water pipe.

  20. DISCONNECT WATER BY-PASS HOSE


    1. Detach the 4 water by-pass hose clamps.

    2. Disconnect the No. 7 water by-pass hose labeled A in the illustration.

    3. Disconnect the No. 4 water by-pass hose labeled B in the illustration.

    4. Disconnect the No. 3 water by-pass hose labeled C in the illustration.

    5. Disconnect the No. 8 water by-pass hose labeled D in the illustration.

    6. Disconnect the No. 6 water by-pass hose labeled E in the illustration.

    7. Disconnect the No. 5 water by-pass hose labeled F in the illustration.

      A00JVKBE01

  21. REMOVE NO. 1 VACUUM TRANSMITTING PIPE


    1. A00JWCY

      Disconnect the vacuum hose from the intake manifold.

    2. Remove the bolt and No. 1 vacuum transmitting pipe.

  22. REMOVE WIRING HARNESS CLAMP BRACKET


    1. Disconnect the glow plug connector.

    2. A00JZIR

      Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.

    3. A00JXS6

      Remove the bolt and wiring harness clamp bracket.

  23. REMOVE NO. 3 ENGINE COVER BRACKET


    1. A00JX5B

      Remove the 2 nuts and No. 3 engine cover bracket.

  24. REMOVE ENGINE COVER BRACKET INSULATOR


    1. A00JWHL

      Remove the 2 nuts and 2 engine cover bracket insulators.

  25. REMOVE NO. 4 ENGINE COVER BRACKET


    1. A00JWRU

      Remove the bolt and No. 4 engine cover bracket.

  26. REMOVE AIR CONNECTOR STAY


    1. A00JXFA

      Disconnect the 4 injector connectors and detach the 3 wire harness clamps.

    2. A00K1D7E01
      Text in Illustration
      *1 No. 1 Fuel Pipe

      Remove the bolt labeled A and disconnect the No. 1 fuel pipe from the air connector stay.

    3. Remove the 3 bolts and air connector stay.

  27. REMOVE EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY


    1. A00JWTF

      Disconnect the fuel pressure sensor connector from the common rail.

    2. Remove the 4 nuts, 3 bolts and EGR cooler with No. 2 EGR valve.

    3. Remove the 2 gaskets from the cylinder head and electric EGR control valve.

      A00JXENE01
      Text in Illustration
      *1 Gasket - -

  28. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Disconnect the electric EGR control valve connector.

    2. A00JVBVE01
      Text in Illustration
      *1 Intake Air Connector

      Remove the electric EGR control valve and gasket from the intake air connector.

  29. DISCONNECT WIRE HARNESS


    1. A00JYTX

      Remove the bolt and disconnect the wire harness.

    2. A00K074

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  30. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A00JZBI

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  31. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A00JW2S

      Remove the bolt and emission control valve bracket.

  32. REMOVE THROTTLE BODY BRACKET


    1. A00K044

      Remove the 3 bolts and throttle body bracket.

  33. REMOVE NO. 1 GAS FILTER


    1. A00JZLL

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  34. REMOVE GAS FILTER BRACKET


    1. A00K1HA

      Detach the clamp and disconnect the wire harness.

    2. A00K059

      Remove the bolt and gas filter bracket.

  35. REMOVE INTAKE AIR CONNECTOR


    1. A00JWYM

      Remove the 3 bolts, intake air connector and gasket.

  36. REMOVE NO. 1 FUEL PIPE


    1. Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

      A00XH74E01
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A00XFQT Union Bolt - -

  37. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XCX9

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A00XCYIE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  38. REMOVE NO. 2 FUEL PIPE


    1. A00XIX4

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A00XHOQ Union Bolt
      A00XFQT Fuel Check Valve

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

  39. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A00XGZK

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A00XFQT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  40. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00XET4

      Remove the 3 bolts.

      Text in Illustration
      A00XFQT Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  41. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XEDI

      Remove the 4 bolts and No. 2 cylinder head cover.

  42. REMOVE VENTILATION PIPE


    1. A00JWRJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  43. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A00XD84E01

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

    2. A00XH2E

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    3. A00XCKH

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  44. REMOVE INJECTOR ASSEMBLY


    1. A00XFVDE04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and 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.

    2. A00XDIKE02

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle 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.

  45. REMOVE NO. 1 RADIATOR HOSE

    A00O8GJ

  46. REMOVE FAN SHROUD


    1. A00O3CJ

      Disconnect the No. 1 water by-pass hose and detach the 2 clamps from the fan shroud.

    2. Disconnect the No. 2 water by-pass hose from the radiator reservoir.

    3. Remove the 3 bolts and radiator reservoir.

    4. for Automatic Transmission:


      1. A00O6YT

        Remove the inlet and outlet oil cooler hoses and detach the clamp from the fan shroud.

      2. Disconnect the 2 oil cooler hoses from the radiator.

    5. A00O5ZQ

      Loosen the 4 nuts holding the fan with fluid coupling.

    6. Remove the fan and generator V belt Click here.

    7. A00O6LU

      Remove the 2 bolts holding the fan shroud.

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

      Note

      Be careful not to damage the radiator core.

    9. Detach the No. 2 water by-pass hose from the hose clamp on the fan shroud.

    10. A00O6JL

      Remove the No. 2 water by-pass hose from the water inlet.

    11. Remove the fan pulley from the water pump.

  47. REMOVE NO. 1 TIMING BELT COVER


    1. A0094PCE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  48. REMOVE TIMING BELT


    1. A0098L2E05
      Text in Illustration
      *1 Timing Mark

      Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A00960LE01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A0098I0E02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.

  49. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  50. REMOVE CAMSHAFT TIMING PULLEY


    1. A00O9HVE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  51. REMOVE NO. 2 TIMING BELT COVER


    1. A00O7OS

      Remove the 4 bolts, nut and No. 2 timing belt cover.

  52. REMOVE CAMSHAFT


    1. A00O46RE03
      Text in Illustration
      *1 Key Groove

      Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

    2. A00O5CUE01

      Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

    3. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.