CAMSHAFT REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354N01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST

      PZ4TB-04941-79

    • 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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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  3. REMOVE RADIATOR ASSEMBLY

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  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  5. REMOVE ENGINE COVER

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  6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

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  7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  8. DISCONNECT ENGINE WIRE

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  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  10. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

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  11. REMOVE NO. 1 VACUUM PIPE

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  12. REMOVE INTAKE MANIFOLD

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  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  14. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  15. REMOVE COMMON RAIL ASSEMBLY

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  16. REMOVE CAMSHAFT POSITION SENSOR

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  17. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

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  18. REMOVE INJECTOR ASSEMBLY

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  19. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A315445

      Remove the plug from the cylinder block.

    2. A318549N01

      Set SST (A) to the plug hole of the cylinder block.

      SST (A)

      PZ4TB-04951-26

    3. A318377C01

      *1

      Flywheel with Damper Assembly

      *a

      Groove

      Using SST (B), turn the crankshaft pulley clockwise until SST (A) fits into the groove of the flywheel with damper assembly.

      SST (B)

      PZ4TB-04933-80

    4. Using SST (A), hold the flywheel with damper assembly.

      SST (A)

      PZ4TB-04951-26

    5. Remove SST.

    6. Install the plug to the cylinder block.

  20. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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  21. REMOVE VACUUM CONTROL VALVE BRACKET

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  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A318362

      Using an E10 "TORX" socket wrench, loosen the 17 bolts and remove the cylinder head cover sub-assembly.

      Tip:

      The bolts cannot be removed from the cylinder head cover sub-assembly.

    2. A319787

      Remove the 5 gaskets from the cylinder head cover sub-assembly.

  23. SECURE CAMSHAFT AND NO. 2 CAMSHAFT

    1. A318364C01

      *a

      Mark (E) (Intake Side)

      *b

      Mark (A) (Exhaust Side)

      Check that the mark (E) and mark (A) of the camshaft and No. 2 camshaft are facing upward.

      Note:

      If the marks of the camshaft and No. 2 camshaft are not aligned as shown in the illustration, set No. 1 cylinder to TDC again.

    2. A318365C01

      *a

      Timing Mark

      Check the camshaft and No. 2 camshaft timing marks.

    3. A318366C01

      *a

      No Clearance

      Set SST to secure the camshaft and No. 2 camshaft.

      SST

      PZ4TB-04961-12

      Note:

      Make sure there is no clearance between SST and the camshaft housing sub-assembly.

  24. REMOVE NO. 1 TURBO INSULATOR

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  25. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  26. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    1. A318368

      Using a 24 mm socket wrench, remove the No. 2 chain tensioner assembly.

  27. REMOVE NO. 2 ENGINE HANGER

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  28. REMOVE NO. 2 TIMING CHAIN GUIDE

    1. A318373

      Using a T45 "TORX" socket wrench, remove the bolt and No. 2 timing chain guide.

  29. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

    1. A318369

      Using an E10 "TORX" socket wrench, remove the 3 bolts and the camshaft timing sprocket.

      Note:

      Do not drop the No. 2 chain sub-assembly into the gap between the cylinder block and timing chain cover plate.

    2. A318371

      Suspend the No. 2 chain sub-assembly with a string or equivalent.

    3. Remove SST from the camshaft and No. 2 camshaft.

    4. A318363N01

      Using an E8 "TORX" socket wrench, uniformly loosen the 20 bolts 180° in several steps in the sequence shown in the illustration.

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

    6. Remove the 5 intake camshaft bearing caps and 5 exhaust camshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

    7. Remove the camshaft and No. 2 camshaft.

  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A318372N01

      Using an E10 "TORX" socket wrench, remove the 14 bolts and camshaft housing sub-assembly.

    2. A319789

      Remove the 4 gaskets.

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

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

      Tip:

      Arrange the removed parts in the correct order.

  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

      Tip:

      Arrange the removed parts in the correct order.