CAMSHAFT REMOVAL

PROCEDURE


  1. DRAIN ENGINE OIL

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  2. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  3. REMOVE REAR ENGINE UNDER COVER RH

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  4. REMOVE FAN AND GENERATOR V BELT

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  5. REMOVE NO. 2 INTERCOOLER COOLING WATER PIPE


    1. B008H3YC02
      *1 No. 1 Turbo Water Hose
      *2 No. 1 Sub-radiator Hose
      *3 No. 6 Sub-radiator Hose

      Slide the hose clip and disconnect the No. 6 sub-radiator hose from the No. 2 water by-pass pipe.

    2. Slide the hose clip and disconnect the No. 1 turbo water hose from the No. 2 intercooler cooling water pipe.

    3. Slide the hose clip and disconnect the No. 1 sub-radiator hose from the No. 2 intercooler cooling water pipe.

    4. Remove the bolt and No. 2 intercooler cooling water pipe.

  6. REMOVE NO. 3 INTERCOOLER COOLING WATER PIPE

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  7. REMOVE IGNITION COIL ASSEMBLY

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  8. DISCONNECT ENGINE WIRE


    1. B008J7D

      Disconnect the 5 connectors.

    2. Remove the 3 bolts and disconnect the engine wire.

  9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  10. REMOVE VACUUM PUMP ASSEMBLY

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  11. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B008GXYC02
      *a Paint Mark
      *b Timing Mark (Groove)
      *c Timing Mark "0"

      Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

    3. Place paint marks on the chain sub-assembly in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

  12. REMOVE TIMING CHAIN COVER PLATE

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  13. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B008HXSC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    2. B008ILAC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

    3. B008I7NC02
      *a Stopper Plate
      *b Pin

      Align the holes of the stopper plate and No. 1 chain tensioner assembly, and insert a pin into the stopper plate hole to lock the No. 1 chain tensioner assembly.

    4. B008HXSC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    5. B008H21

      Remove the bolt and nut, No. 1 chain tensioner assembly and gasket.

      Note

      Make sure not to drop the gasket inside the timing chain cover assembly.

    6. B008ILAC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

  14. REMOVE TIMING CHAIN GUIDE

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  15. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  16. REMOVE CAMSHAFT TIMING GEAR BOLT


    1. B008HP1C02
      *a Hold
      B008IUL Turn

      Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft.

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  17. REMOVE CAMSHAFT BEARING CAP


    1. B008HTBN03

      Using several steps, remove the 11 bearing cap bolts in the sequence shown in the illustration.

    2. B008IMDN02

      Using several steps, remove the 10 bearing cap bolts in the sequence shown in the illustration.

      Note

      Make sure to loosen the bearing cap bolts evenly while holding the camshaft horizontally.

    3. Remove the 4 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  18. REMOVE CAMSHAFT


    1. B008IXZ

      Raise the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

      Note

      Be careful not to damage the camshaft or camshaft timing gear assembly with the wrench.

  19. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B008I31

      Remove the camshaft timing gear assembly.

      Note


      • Do not disassemble the camshaft timing gear assembly.

      • Be careful not to damage the camshaft timing gear assembly with the wrench.

  20. REMOVE NO. 2 CAMSHAFT


    1. B008J6K

      Remove the No. 2 camshaft from the camshaft housing sub-assembly.

    2. B008ISG

      Suspend the chain sub-assembly with a string or equivalent as shown in the illustration.

      Note

      Be careful not to drop the chain sub-assembly inside the timing chain cover assembly.

  21. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B008HSLC02
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. B008IP0

      Remove the bolt and camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the No. 2 camshaft and camshaft timing exhaust gear assembly.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  22. REMOVE OIL CONTROL VALVE FILTER

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  23. REMOVE NO. 1 CAMSHAFT BEARING

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  24. REMOVE NO. 2 CAMSHAFT BEARING

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  25. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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