CAMSHAFT REMOVAL

CAUTION / NOTICE / HINT

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 dirt contamination.

    Cover the generator assembly with suitable materials.

    Failure to comply with this procedure may result in a generator assembly malfunction.

  • A316354E01

    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

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 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 RADIATOR ASSEMBLY

    (Click here)

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    (Click here)

  5. REMOVE ENGINE COVER

    Click here

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

    Click here

  7. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  9. DISCONNECT ENGINE WIRE

    Click here

  10. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  11. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

    Click here

  12. REMOVE NO. 1 VACUUM PIPE

    Click here

  13. REMOVE INTAKE MANIFOLD

    Click here

  14. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE COMMON RAIL ASSEMBLY

    Click here

  17. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  18. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  19. REMOVE INJECTOR ASSEMBLY

    Click here

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A315445

      Remove the plug from the cylinder block.

    2. A318549E01

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

      SST(A)

      PZ4TB-04951-26

    3. A318377E03

      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

      Table 1. Text in Illustration

      *1

      Flywheel with Damper Assembly

      *a

      Groove

    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.

  21. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  22. REMOVE VACUUM CONTROL VALVE BRACKET

    Click here

  23. 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:

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

    2. A319787

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

  24. HOLDING CAMSHAFT AND NO. 2 CAMSHAFT

    1. A318364E03

      Check that the camshaft and No. 2 camshaft on the camshaft housing sub-assembly as shown in the illustration so that mark E and mark A face upward.

      Table 2. Text in Illustration

      *a

      Mark E (Intake Side)

      *b

      Mark A (Exhaust Side)
      Note:

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

    2. A318365E02

      Check the camshaft and No. 2 camshaft timing marks.

      Table 3. Text in Illustration

      *a

      Timing Mark
    3. A318366E02

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

      SST

      PZ4TB-04961-12

      Table 4. Text in Illustration

      *a

      No Clearance
      Note:

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

  25. REMOVE NO. 1 TURBO INSULATOR

    Click here

  26. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  27. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    1. A318368

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

  28. REMOVE NO. 2 ENGINE HANGER

    Click here

  29. REMOVE NO. 2 TIMING CHAIN GUIDE

    1. A318373

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

  30. 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 securing the camshaft and No. 2 camshaft.

    4. A318363E03

      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.

  31. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    1. A318372E03

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

    2. A319789

      Remove the 4 gaskets.

  32. 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.

  33. 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.