CAMSHAFT REMOVAL

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.


  1. 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. 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. REMOVE ENGINE ASSEMBLY

    Click here

  4. 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. REMOVE GENERATOR ASSEMBLY


    1. A01ISLO

      Remove the 3 bolts and generator.

  6. REMOVE VACUUM PUMP ASSEMBLY


    1. A01IOLN

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump.

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

  7. REMOVE IDLER PULLEY COVER PLATE


    1. A01INKKE01
      Text in Illustration
      *1 Tape

      Using a screwdriver, remove the idler pulley cover plate.

      Tech Tips

      Tape the screwdriver tip before use.

  8. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01INUC

      Remove the bolt and No. 1 idler pulley.

  9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01IQMTE01
      Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley

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

  10. 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. REMOVE ENGINE MOUNTING BRACKET


    1. A01IQJU

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

  12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01IU2Z

      Remove the 3 bolts and V-ribbed belt tensioner.

      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. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01IU98E01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Disconnect the No. 6 and No. 7 water by-pass hoses.

    2. A01IS0N

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

  14. REMOVE NO. 7 WATER BY-PASS HOSE

    A01IUFE

  15. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A01INDM

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

  16. REMOVE EGR VALVE BRACKET


    1. A01IPI2

      Remove the 3 bolts and 2 brackets.

  17. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01
      Text in Illustration
      *1 Nut

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

  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve assembly and gasket.

  19. 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. 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. 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. REMOVE NO. 4 FUEL HOSE

    A01IORV

  23. REMOVE COMMON RAIL ASSEMBLY


    1. A01ITVG

      Remove the 2 bolts and common rail.

  24. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IQK4

      Remove the intake manifold insulator from the intake manifold.

  25. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  26. REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

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

  27. REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  28. REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  29. REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

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

  30. REMOVE INTAKE MANIFOLD


    1. A01IOHHE01
      Text in Illustration
      *1 Nut

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

  31. 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. REMOVE OIL COOLER ASSEMBLY


    1. A01IRXA

      Remove the 5 bolts and oil cooler assembly.

    2. Remove the 3 O-rings from the oil cooler bracket.

  33. REMOVE NO. 6 WATER BY-PASS HOSE

    A01INLK

  34. REMOVE NO. 8 WATER BY-PASS HOSE

    A01IO0M

  35. 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. REMOVE NO. 1 TURBO OIL PIPE


    1. A01INN5

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

  37. REMOVE NO. 1 OIL COOLER BRACKET


    1. A01ISIE

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

      Text in Illustration
      A01ISER Nut

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

  38. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A01INKR

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

  39. 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. REMOVE NO. 4 WATER BY-PASS HOSE

    A01ITEU

  41. REMOVE WATER INLET HOUSING


    1. A01IUI2

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  42. REMOVE FUEL HOSE PROTECTOR


    1. A01INWG

      Remove the bolt and fuel hose protector.

  43. REMOVE FUEL TUBE SUB-ASSEMBLY


    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.

      Text in Illustration
      A01ISER Check Valve

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

  44. REMOVE NO. 3 FUEL HOSE

    A01IP50

  45. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01IO69

      Remove the check valve and gasket.

      Text in Illustration
      A01ISER Check Valve

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

  46. 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.

  47. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01IOF9

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

  48. 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.

  49. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01ITBIE01
      Text in Illustration
      *a Pinch

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

    2. A01IQO4

      Disconnect the 2 vacuum hoses.

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

  50. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. Disconnect the vacuum regulating valve connector.

    2. A01IQN9

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  51. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IO8X

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

  52. REMOVE PCV HOSE

    A01IP4G

  53. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  54. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IN9G

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

      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.

  55. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01IU0W

      Remove the 18 bolts and 2 nuts.

      Text in Illustration
      A01ISER Nut
    2. A01IPIFE06

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing chain cover.

      • Be careful not to damage the contact surfaces of the oil pan.

  56. REMOVE OIL FILTER ELEMENT


    1. A01INHEE08
      Text in Illustration
      *1 Oil filter drain pipe
      *2 Hose

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

    2. A01IPQG

      Remove the oil filter drain plug.

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

    4. A01IQO9E01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Drain Pipe

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

    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.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    8. A01ITUTE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    9. A01ITLEE01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

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

      Note

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

  57. REMOVE OIL FILTER BRACKET


    1. A01IU3I

      Remove the 4 bolts and oil filter bracket.

    2. A01IOF2

      Remove the gasket from the oil filter bracket.

  58. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01IQWZ

      Remove the 3 bolts and oil strainer.

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

  59. REMOVE CAMSHAFT POSITION SENSOR


    1. A01IN28

      Remove the bolt and sensor.

  60. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A01IP27

      Using a clip remover, remove the clip.

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

  61. REMOVE WATER PUMP ASSEMBLY


    1. A01INY2

      Remove the 7 bolts, water pump assembly and gasket.

  62. REMOVE CRANKSHAFT PULLEY


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


      1. A01ITG4E01
        Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark

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

    2. A01IUCUE01
      Text in Illustration
      *1 Matchmark
      *2 Timing Mark

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

      Tech Tips

      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.

      Tech Tips

      The timing chain has 2 yellow-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.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A01IR03E01

      Using SST, remove the pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  63. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01IQAE

      Remove the 13 bolts and seal washer.

      Text in Illustration
      A01ISER Bolt and Seal Washer
    2. A01ITQ6

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

      Note

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01ISRGE01
      Text in Illustration
      *1 Gasket
      *2 O-Ring

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

  64. 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.

  65. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ITJ2E01
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

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

      SST
      09240-00020   ( 09242-00200 )
    3. A01IRKJ

      Remove the 2 bolts and No. 1 chain tensioner.

  66. REMOVE CHAIN TENSIONER SLIPPER

    A01INFL

  67. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01ITAJ

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

  68. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01IOA0

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

    2. Remove the camshaft timing sprocket and chain.

  69. REMOVE OIL PUMP DRIVE GEAR


    1. A01IQAN

      Remove the oil pump drive gear from the crankshaft.

  70. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01IT2D

      Remove the crankshaft timing sprocket.

  71. REMOVE CAMSHAFT


    1. A01IU3D

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

    2. A01ITINE01
      Text in Illustration
      *1 Oil Pipe Seat
      *2 No. 4 Camshaft Bearing Cap

      Remove the 2 oil pipe seats.

    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.

      Tech Tips

      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.

  72. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01IRYG

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

  73. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01IT5U

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

      Tech Tips

      Arrange the removed parts in the correct order.