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CAMSHAFT REMOVAL

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Click here Click here
Note:

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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

Click here
  1. 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).

  2. 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).

  3. Click here

    REMOVE ENGINE ASSEMBLY

    (Click here)

  4. Click here

    DISCONNECT ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine, remove the bracket bolts and disconnect the engine wire from the engine.

  5. Click here

    REMOVE GENERATOR ASSEMBLY


    1. A01IN5D

      Remove the terminal cap.

    2. Disconnect the generator connector and detach the clamp.

    3. Remove the nut and bolt, and disconnect the generator wire.

    4. A01ISLO

      Remove the 3 bolts and generator assembly.

  6. Click here

    REMOVE VACUUM PUMP ASSEMBLY


    1. A01IOLN

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump assembly.

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

  7. Click here

    REMOVE IDLER PULLEY COVER PLATE


    1. A01INKKE01

      Using a screwdriver, remove the idler pulley cover plate.

      Table 1. Text in Illustration
      *1 Tape
      Tip:

      Tape the screwdriver tip before use.

  8. Click here

    REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01INUC

      Remove the bolt and No. 1 idler pulley sub-assembly.

  9. Click here

    REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01IQMTE01

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly.

      Table 2. Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley Sub-assembly
  10. Click here

    REMOVE NO. 4 WATER BY-PASS PIPE


    1. A01IU1R

      Remove the bolt and No. 4 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 4 water by-pass pipe.

  11. Click here

    REMOVE ENGINE MOUNTING BRACKET


    1. A01IQJU

      Remove the 4 bolts, 2 nuts and engine mounting bracket.

  12. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01IU2Z

      Remove the 3 bolts and V-ribbed belt tensioner assembly.

      Note:

      As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during removal.

  13. Click here

    REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01IU98E01

      Slide the 2 clamps and disconnect the No. 6 water by-pass hose and No. 7 water by-pass hose from the diesel throttle body assembly.

      Table 3. Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
    2. A01IS0N

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

  14. Click here

    REMOVE NO. 7 WATER BY-PASS HOSE


    1. A01IUFE

      Slide the clamp and remove the No. 7 water by-pass hose from the electric EGR control valve assembly.

  15. Click here

    DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. Slide the clamp and disconnect the No. 8 water by-pass hose from the electric EGR control valve assembly.

  16. Click here

    REMOVE EGR VALVE BRACKET


    1. A01IPI2

      Remove the 3 bolts and 2 EGR valve brackets.

  17. Click here

    REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01

      Remove the 3 bolts, 2 nuts, No. 2 EGR pipe sub-assembly and 2 gaskets.

      Table 4. Text in Illustration
      *1 Nut
  18. Click here

    REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve assembly and gasket.

  19. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IN7K

      Remove the 2 bolts and engine oil level dipstick guide.

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

  20. Click here

    REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note:

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A01ITN1

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

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe sub-assembly.

  21. Click here

    REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A01IO2G

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 union nuts at the common rail assembly end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 union nuts at the injector assembly end of the injection pipes.

    4. Remove the 4 injection pipes.

  22. Click here

    REMOVE NO. 4 FUEL HOSE


    1. A01IORV

      Slide the 2 clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe and common rail assembly.

  23. Click here

    REMOVE COMMON RAIL ASSEMBLY


    1. A01ITVG

      Remove the 2 bolts and common rail assembly.

  24. Click here

    REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IO3Y

      Remove the intake manifold insulator from the intake manifold.

  25. Click here

    REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and diesel turbo pressure sensor.

  26. Click here

    REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  27. Click here

    REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  28. Click here

    REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  29. Click here

    REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  30. Click here

    REMOVE INTAKE MANIFOLD


    1. A01IOHHE01

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

      Table 5. Text in Illustration
      *1 Nut

    2. Remove the gasket from the cylinder head.

  31. Click here

    REMOVE WATER BY-PASS HOSE


    1. A01IQEK

      Slide the 2 clamps and remove the water by-pass hose from the water outlet and oil cooler assembly.

  32. Click here

    REMOVE OIL COOLER ASSEMBLY


    1. A01IRXA

      Remove the 5 bolts and oil cooler assembly.

    2. for CCo:

      Remove the 3 O-rings from the No. 1 oil cooler bracket.

    3. for DPF:

      Remove the 3 gaskets from the No. 1 oil cooler bracket.

  33. Click here

    REMOVE NO. 6 WATER BY-PASS HOSE


    1. A01INLK

      Slide the clamp and remove the No. 6 water by-pass hose from the water outlet.

  34. Click here

    REMOVE NO. 8 WATER BY-PASS HOSE


    1. A01IO0M

      Slide the clamp and remove the No. 8 water by-pass hose from the No. 3 water by-pass pipe.

  35. Click here

    REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01IT3O

      Remove the 2 bolts and No. 3 water by-pass pipe.

    2. Remove the O-ring from the No. 3 water by-pass pipe.

  36. Click here

    REMOVE NO. 1 TURBO OIL PIPE


    1. A01INN5

      Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.

  37. Click here

    REMOVE NO. 1 OIL COOLER BRACKET


    1. A01IU37E01

      Remove the 6 bolts, nut and No. 1 oil cooler bracket.

      Table 6. Text in Illustration
      *A for CCo
      *B for DPF
      A01ISER Nut

    2. for CCo:

      Remove the 3 O-rings from the No. 1 oil cooler bracket.

    3. for DPF:

      Remove the 3 gaskets from the No. 1 oil cooler bracket.

  38. Click here

    REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A01INKR

      Remove the No. 1 cylinder block insulator from the cylinder block.

  39. Click here

    REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01IP5C

      Remove the 2 bolts and No. 2 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 2 water by-pass pipe.

  40. Click here

    REMOVE NO. 4 WATER BY-PASS HOSE


    1. A01ITEU

      Slide the 2 clamps and remove the No. 4 water by-pass hose from the water inlet housing and cylinder head sub-assembly.

  41. Click here

    REMOVE WATER INLET HOUSING


    1. A01IUI2

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  42. Click here

    REMOVE NO. 2 FUEL PIPE (for CCo)


    1. A01IN5Z

      Remove the check valve and gasket.

      Table 7. Text in Illustration
      A01ISER Check Valve

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

  43. Click here

    REMOVE FUEL HOSE PROTECTOR (for DPF)


    1. A01INWG

      Remove the bolt and fuel hose protector.

  44. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. A01IT57

      Disconnect the exhaust fuel addition injector connector.

    2. A01IQ6B

      Turn the retainer as shown in the illustration.

    3. A01IUL8

      Disconnect the fuel tube sub-assembly from the exhaust fuel addition injector assembly.

    4. A01INMW

      Remove the check valve and gasket.

      Table 8. Text in Illustration
      A01ISER Check Valve

    5. Remove the union bolt, gasket and fuel tube sub-assembly.

  45. Click here

    REMOVE NO. 3 FUEL HOSE


    1. A01IP50

      Slide the 2 clamps and remove the No. 3 fuel hose from the supply pump assembly and No. 2 nozzle leakage pipe.

  46. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01IO69

      Remove the check valve and gasket.

      Table 9. Text in Illustration
      A01ISER Check Valve

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

  47. Click here

    REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A01ISVS

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  48. Click here

    REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01IOF9

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

  49. Click here

    REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector assembly.

      Note:

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.

  50. Click here

    REMOVE VACUUM REGULATING VALVE ASSEMBLY (for CCo)


    1. Disconnect the vacuum regulating valve connector.

    2. A01IQN9

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  51. Click here

    REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01ITBIE01

      Pinch the clip as shown in the illustration, and pull out the VSV connector.

      Table 10. Text in Illustration
      *a Pinch
    2. A01IQO4

      Disconnect the 2 vacuum hoses.

    3. Using a 4 mm hexagon socket wrench, remove the 2 bolts and VSV.

  52. Click here

    REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IO8X

      for CCo:

      Detach the 10 clamps and remove the 2 vacuum transmitting hoses.

    2. A01IP7L

      for DPF:

      Detach the 8 clamps and remove the 2 vacuum transmitting hoses.

  53. Click here

    REMOVE NO. 1 WIRING HARNESS CLAMP BRACKET (for DPF)


    1. A01ISVH

      Remove the bolt and No. 1 wiring harness clamp bracket.

  54. Click here

    REMOVE VENTILATION HOSE


    1. A01IP4G

      Slide the clamp and remove the ventilation hose from the cylinder head cover sub-assembly.

  55. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY

  56. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IN9G

      Remove the 4 nozzle holder clamp seats, 14 bolts, nut and cylinder head cover sub-assembly.

      Table 11. Text in Illustration
      A01ISM9 Bolt
      A01ISER Nozzle Holder Clamp Seat
      A01IQPE Nut
    2. A01IN7I

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

  57. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01IN6LE01

      Remove the 18 bolts and 2 nuts.

      Table 12. Text in Illustration
      *A for CCo
      *B for DPF
      A01ISER Nut
    2. A01IPIFE06

      Insert the blade of an oil pan seal cutter between the No. 2 oil pan sub-assembly and cylinder block, cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note:

      • Do not use the oil pan seal cutter for the area between the No. 2 oil pan sub-assembly and timing chain cover sub-assembly.

      • Be careful not to damage the contact surfaces of the No. 2 oil pan sub-assembly.

  58. Click here

    REMOVE OIL FILTER ELEMENT


    1. A01INHEE08

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the oil filter drain pipe.

      Table 13. Text in Illustration
      *1 Oil filter drain pipe
      *2 Hose
    2. A01IU62E01

      Remove the oil filter drain plug.

      Table 14. Text in Illustration
      *A for CCo
      *B for DPF

    3. Remove the O-ring from the oil filter drain plug and install it to an oil filter drain pipe.

    4. A01IQO9E01

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

      Table 15. Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Drain Pipe

    5. Remove the oil filter drain pipe.

    6. Apply a light coat of engine oil to a new O-ring and install it to the oil filter drain plug.

    7. Install the oil filter drain plug to the oil filter cap.

      13 N*m 127 kgf*cm 9 ft.*lbf
    8. A01IRTKE02

      Using SST, remove the oil filter cap.

      09228-06501
      Table 16. Text in Illustration
      *A for CCo *B for DPF
    9. A01ITLEE01

      Remove the oil filter element and O-ring from the oil filter cap.

      Table 17. Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring
      Note:

      Be sure to remove the cap O-ring by hand without using any tools to prevent damage to the cap O-ring groove.

  59. Click here

    REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY (for DPF)


    1. A01IQQX

      Detach the wire harness clamp and disconnect the oil pressure switching valve connector.

    2. Remove the bolt and oil pressure switching valve assembly.

  60. Click here

    REMOVE OIL FILTER BRACKET


    1. A01INIDE01

      Remove the 4 bolts and oil filter bracket.

      Table 18. Text in Illustration
      *A for CCo
      *B for DPF
    2. A01IS5LE01

      Remove the gasket from the oil filter bracket.

      Table 19. Text in Illustration
      *A for CCo
      *B for DPF
  61. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01IPZE

      Remove the 3 bolts and oil strainer sub-assembly.

    2. Remove the O-ring from the oil strainer sub-assembly.

  62. Click here

    REMOVE CAMSHAFT POSITION SENSOR


    1. for DPF:

      Detach the wire harness clamp.

      Table 20. Text in Illustration
      *A for CCo
      *B for DPF

    2. Disconnect the camshaft position sensor connector.

    3. Remove the bolt and camshaft position sensor.

  63. Click here

    DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A01IPTRE01

      Using a clip remover, remove the clip.

      Table 21. Text in Illustration
      *A for CCo
      *B for DPF

    2. Remove the bolt and disconnect the crankshaft position sensor wire harness.

  64. Click here

    REMOVE WATER PUMP ASSEMBLY


    1. A01INY2

      Remove the 7 bolts, water pump assembly and gasket.

  65. Click here

    REMOVE CRANKSHAFT PULLEY


    1. Set the No. 1 piston to TDC/compression.


      1. A01ITG4E01

        Turn the crankshaft pulley clockwise to align the timing mark on the crankshaft pulley with the timing pointer of the timing chain cover sub-assembly.

        Table 22. Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark
    2. A01IR1UE01

      Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Table 23. Text in Illustration
      *A for CCo
      *B for DPF
      *1 Matchmark
      *2 Timing Mark
      Tip:

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/compression).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tip:

      The chain sub-assembly has 2 colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A01IUJCE01

      Turn the crankshaft by approximately 90° in the direction of engine revolution from the point where the No. 1 piston is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

    5. A01IPB5E01

      Using SST, loosen the pulley bolt.

      09213-58014 91551-80840
      09330-00021
    6. A01IR03E01

      Using SST, remove the pulley bolt and crankshaft pulley.

      09950-50013 09951-05010 09952-05010 09953-05020 09954-05021
  66. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01INA5E01

      Remove the 13 bolts and seal washer.

      Table 24. Text in Illustration
      *A for CCo *B for DPF
      A01ISER Bolt and Seal Washer - -
    2. A01ITIEE01

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Table 25. Text in Illustration
      *A for CCo *B for DPF
      Note:

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block, stiffening crankcase and timing chain cover sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

    3. A01INE5E01

      Remove the gasket and O-ring from the timing chain cover sub-assembly.

      Table 26. Text in Illustration
      *A for CCo
      *B for DPF
      *1 Gasket
      *2 O-Ring
  67. Click here

    REMOVE SUPPLY PUMP ASSEMBLY


    1. A01IQWG

      Remove the 2 bolts, supply pump assembly and No. 1 supply pump drive coupling.

    2. Remove the O-ring from the supply pump assembly.

  68. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ITJ2E01

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

      Table 27. Text in Illustration
      *1 Plunger
      *2 Stopper Plate

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      09240-00020 09242-00200
    3. A01IRKJ

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

  69. Click here

    REMOVE CHAIN TENSIONER SLIPPER

  70. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01ITAJ

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

  71. Click here

    REMOVE OIL PUMP DRIVE GEAR


    1. A01IQAN

      Remove the oil pump drive gear from the crankshaft.

  72. Click here

    REMOVE CAMSHAFT TIMING SPROCKET


    1. A01IN83E01

      Remove the 4 bolts from the camshaft timing sprocket while holding the hexagonal portion of the No. 2 camshaft with a wrench.

      Table 28. Text in Illustration
      *A for CCo
      *B for DPF

    2. Remove the camshaft timing sprocket and chain sub-assembly.

  73. Click here

    REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01IT2D

      Remove the crankshaft timing sprocket.

  74. Click here

    REMOVE CAMSHAFT


    1. A01IU3D

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

    2. A01ITINE01

      Remove the 2 oil pipe seats.

      Table 29. Text in Illustration
      *1 Oil Pipe Seat
      *2 No. 4 Camshaft Bearing Cap

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

    4. Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tip:

      Do not remove the No. 4 camshaft bearing cap.

    5. Remove the camshaft and No. 2 camshaft.

    6. A01ITJ0

      Remove the No. 2 camshaft bearing cap.

  75. Click here

    REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01IRYG

      Remove the 16 No. 1 valve rocker arm sub-assemblies.

  76. Click here

    REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01IT5U

      Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.