CAMSHAFT REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE

  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 hereClick hereClick hereClick hereClick 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 hereClick hereClick hereClick hereClick hereClick here

  3. REMOVE ENGINE ASSEMBLY

    Click hereClick here

  4. DISCONNECT ENGINE WIRE

    Click here

  5. REMOVE GENERATOR ASSEMBLY

    Click here

  6. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  7. REMOVE IDLER PULLEY COVER PLATE

    Click here

  8. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  11. REMOVE ENGINE MOUNTING BRACKET

    Click here

  12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  13. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  14. REMOVE NO. 7 WATER BY-PASS HOSE

    Click here

  15. DISCONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  16. REMOVE EGR VALVE BRACKET

    Click here

  17. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  19. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  20. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  21. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  22. REMOVE NO. 4 FUEL HOSE

    Click here

  23. REMOVE COMMON RAIL ASSEMBLY

    Click here

  24. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  25. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  26. REMOVE NO. 1 GAS FILTER

    Click here

  27. REMOVE GAS FILTER BRACKET

    Click here

  28. REMOVE ENGINE COVER BRACKET

    Click here

  29. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

  30. REMOVE INTAKE MANIFOLD

    Click here

  31. REMOVE WATER BY-PASS HOSE

    Click here

  32. REMOVE OIL COOLER ASSEMBLY

    Click here

  33. REMOVE NO. 6 WATER BY-PASS HOSE

    Click here

  34. REMOVE NO. 8 WATER BY-PASS HOSE

    Click here

  35. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  36. REMOVE NO. 1 TURBO OIL PIPE

    Click here

  37. REMOVE NO. 1 OIL COOLER BRACKET

    Click here

  38. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  39. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  40. REMOVE NO. 4 WATER BY-PASS HOSE

    Click here

  41. REMOVE WATER INLET HOUSING

    Click here

  42. REMOVE FUEL HOSE PROTECTOR

    Click here

  43. REMOVE FUEL TUBE SUB-ASSEMBLY

    Click here

  44. REMOVE NO. 3 FUEL HOSE

    Click here

  45. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    Click here

  46. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  47. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

  48. REMOVE INJECTOR ASSEMBLY

    Click here

  49. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  50. REMOVE VACUUM REGULATING VALVE ASSEMBLY

    Click here

  51. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  52. REMOVE PCV HOSE

    Click here

  53. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  54. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  55. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  56. REMOVE OIL FILTER ELEMENT

    Click here

  57. REMOVE OIL FILTER BRACKET

    Click here

  58. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  59. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  60. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS

    Click here

  61. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  62. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    Click here

  63. REMOVE CRANKSHAFT PULLEY

    Click here

  64. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  65. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  66. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  67. REMOVE CHAIN TENSIONER SLIPPER

    Click here

  68. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  69. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  70. REMOVE OIL PUMP DRIVE GEAR

    Click here

  71. REMOVE CRANKSHAFT TIMING SPROCKET

    Click here

  72. REMOVE CAMSHAFT

    1. A117173

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

    2. A294404C08

      *1

      No. 4 Camshaft Bearing Cap

      *a

      Oil Pipe Seat

      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.

      Tip:

      Do not remove the No. 4 camshaft bearing cap.

    5. Remove the camshaft and No. 2 camshaft.

    6. A202395

      Remove the No. 2 camshaft bearing cap.

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

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

  74. 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.