РАСПРЕДВАЛ СНЯТИЕ


  1. REMOVE ENGINE ASSEMBLY


    1. Remove the engine assembly Click here.

  2. REMOVE GENERATOR ASSEMBLY

    A011BVO

    1. Remove the 2 bolts, nut and generator.

  3. REMOVE GENERATOR BRACKET

    A011866

    1. Remove the bolt and the generator bracket.

  4. REMOVE EGR WITH COOLER PIPE ASSEMBLY

    A01190W

    1. Disconnect the vacuum transmitting hose.

    2. Disconnect the No. 1 vacuum transmitting hose.

    3. A0119Y8

      Disconnect the 2 vacuum hoses and No. 1 oil hose.

    4. Disconnect the No. 2 oil cooler hose.

    5. Disconnect the No. 2 water by-pass hose.

    6. A0119M3

      Remove the 4 bolts, 2 nuts and the EGR with cooler pipe assembly.

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

  5. REMOVE NO. 1 EGR COOLER BRACKET

    A01197G

    1. Disconnect the vacuum hose.

    2. Remove the 2 bolts and the No. 1 EGR cooler bracket.

  6. REMOVE HARNESS BRACKET

    A011AOS

    1. Disconnect the vacuum hose from the vacuum pump.

    2. Remove the bolt and harness bracket.

  7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A0117TJ

    1. Disconnect the No. 4 water by-pass hose.

    2. Disconnect the No. 3 water by-pass hose.

    3. Remove the 2 bolts and the electric EGR control valve.

    4. Remove the gasket from the intake air connector.

  8. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

    A0119J6

    1. Remove the 2 bolts, 2 nuts and the intake air connector with the diesel throttle body.

    2. Remove the gasket from the cylinder head.

  9. REMOVE NO. 2 INJECTION PIPE CLAMP


    1. A0118OJ

      Remove the nut and both sides of the No. 2 injection pipe clamp.

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A0117G5

      Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), separate the union nut from the supply pump first.

    2. Then remove the union nut from the common rail, and remove the fuel inlet pipe.

    3. After removing the fuel inlet pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.

  11. REMOVE NOZZLE LEAKAGE PIPE SET CLAMP

    A011927

    1. Remove the 3 nozzle leakage pipe set clamps.

  12. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    A0118JV

    1. Remove the retainer spring disconnect the nozzle leakage pipe.

    2. A01171XE01
      Text in Illustration
      *1 Lock Bush

      Pull up the lock bush as shown in the illustration and remove the nozzle leakage pipe.

      Note

      Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.

  13. DISCONNECT NO. 2 FUEL HOSE

    A011B0V

    1. Disconnect the No. 2 fuel hose.

  14. REMOVE SUPPLY PUMP ASSEMBLY

    A0119GH

    1. Remove the 3 bolts and supply pump.

    2. A0118J9

      Remove the O-ring.

  15. REMOVE SUPPLY PUMP DRIVE COUPLING


    1. A0119VH

      Remove the supply pump driving coupling.

      Note

      When removing the supply pump, make sure that the drive coupling does not fall off, as it can be easily removed. If the drive coupling falls off, replace it with a new one.

  16. REMOVE NO. 2 OIL COOLER HOSE


    1. A01192S

      Remove the hose clamp.

    2. A0118UH

      Disconnect the 2 clamps and remove the No. 2 oil cooler hose.

  17. REMOVE NO. 4 WATER BY-PASS HOSE

    A0119KJ

    1. Remove the No. 4 water by-pass hose.

  18. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    A011AXH

    1. Disconnect the oil cooler hose.

    2. A0119KW

      Disconnect the water by-pass hose.

    3. A01172X

      Remove the 2 bolts and the water by-pass pipe.

    4. Remove the O-ring from the water by-pass pipe.

  19. REMOVE ENGINE OIL LEVEL DIPSTICK

  20. REMOVE OIL LEVEL DIPSTICK GUIDE

    A0119KF

    1. Remove the 2 bolts and the oil level dipstick guide.

    2. Remove the O-ring from the oil level dipstick guide.

  21. REMOVE NO. 2 CYLINDER HEAD COVER

    A0118GJ

    1. Remove the 2 bolts and the 2 harness brackets.

    2. A011756

      Remove the No. 2 cylinder head cover.

  22. REMOVE CAMSHAFT POSITION SENSOR

    A0118LM

    1. Remove the bolt and harness bracket.

    2. Remove the bolt and camshaft position sensor.

  23. REMOVE VACUUM PUMP ASSEMBLY

    A0118TC

    1. Remove the 2 bolts and vacuum pump.

    2. Remove the 2 O-rings from the vacuum pump.

  24. REMOVE IDLER PULLEY SUB-ASSEMBLY

    A01192A

    1. Remove the bolt and idler pulley.

  25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A0117ML

    1. Remove the 2 bolts and the V-ribbed belt tensioner.

  26. REMOVE HARNESS BRACKET (w/o Air Conditioning System)

    A011AE6

    1. Remove the bolt and harness bracket.

  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A011ABA

      Remove the 12 bolts and the cylinder head cover.

    2. Remove the cylinder head cover gasket from the cylinder head cover.

  28. REMOVE ENGINE MOUNTING BRACKET RH


    1. A0119XF

      Remove the 4 bolts and the engine mounting bracket.

  29. REMOVE NO. 2 TIMING CHAIN COVER

    A0119BE

    1. Remove the clip and the No. 2 timing chain cover.

  30. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

    A011AGCE01

    1. Using SST, hold the crankshaft damper and loosen the crankshaft bolt.

      SST
      09213-58014
      09330-00021
    2. A0118JGE01

      Using SST, remove the crankshaft pulley bolt and the crankshaft pulley.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09956-03020 )

  31. DISCONNECT WATER INLET HOSE LH

    A0119XW

    1. Disconnect the water inlet hose LH.

  32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01177N

      Remove the 20 bolts and the 2 nuts.

    2. A0119VDE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover by prying between the cylinder head and cylinder block.

      Note

      Do not damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    Do not rotate the crankshaft with the chain tensioner removed.


    1. A01181ZE02
      Text in Illustration
      *1 Plunger
      *2 Groove
      *3 Hole

      Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.

    2. A011A5V

      Remove the 2 bolts and the No. 1 chain tensioner.

  34. REMOVE CHAIN TENSIONER SLIPPER


    1. A0118ZG

      Remove the chain tensioner.

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A011A1I

      Remove the 2 bolts and the No. 1 chain vibration damper.

  36. REMOVE CHAIN SUB-ASSEMBLY


    1. A011A1KE01

      Using SST, hold the camshaft timing sprocket.

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

    2. Remove the 3 bolts and the camshaft timing sprocket.

    3. A011AC8

      Remove the camshaft timing sprocket, crankshaft timing sprocket and chain together.

  37. REMOVE CAMSHAFT

    A011A20E02
    Text in Illustration
    *1 No. 3 Camshaft Bearing Cap

    1. Remove the 10 bolts from the camshaft bearing caps by loosening them in the sequence shown in the illustration, and then remove the 5 camshaft bearing caps.

    2. Remove the camshaft.

      Note


      • Using several steps, uniformly loosen the bolts while keeping the camshaft level.

      • Do not remove the No. 3 camshaft bearing cap.