CAMSHAFT(w/ Glow Plug Controller) REMOVAL

PROCEDURE

  1. INSTALL ENGINE TO ENGINE STAND

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  2. REMOVE ENGINE COVER BRACKET

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  3. REMOVE GENERATOR ASSEMBLY

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  4. REMOVE GENERATOR BRACKET

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  5. REMOVE EGR WITH COOLER PIPE ASSEMBLY

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  6. REMOVE NO. 1 EGR COOLER BRACKET

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  7. REMOVE HARNESS BRACKET (for LHD)

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  8. REMOVE HARNESS BRACKET (for RHD)

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  9. REMOVE EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

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  10. REMOVE ENGINE OIL LEVEL DIPSTICK

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  11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  12. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

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  13. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

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  14. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  15. DISCONNECT NO. 1 FUEL HOSE

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  16. DISCONNECT NO. 2 FUEL HOSE

    1. A265733

      Slide the hose clip and disconnect the No. 2 fuel hose from the No. 2 nozzle leakage pipe.

  17. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

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  18. REMOVE FUEL PUMP PROTECTOR

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  19. REMOVE SUPPLY PUMP ASSEMBLY

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  20. REMOVE NO. 2 OIL COOLER HOSE

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  21. REMOVE NO. 4 WATER BY-PASS HOSE

    1. A348744

      Disengage the clamp to separate the No. 4 water by-pass hose from the common rail assembly.

    2. Slide the hose clip and remove the No. 4 water by-pass hose from the water inlet pipe.

  22. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    1. A265735

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

    2. A265736

      Slide the hose clip and disconnect the water by-pass hose from the tube connector.

    3. A265737

      Slide the hose clip and disconnect the oil cooler hose from the water by-pass pipe sub-assembly.

    4. A350450

      Remove the 3 bolts and water by-pass pipe sub-assembly from the No. 2 turbocharger stay, cylinder head sub-assembly, cylinder block sub-assembly and water inlet housing.

    5. Remove the O-ring from the water by-pass pipe sub-assembly.

  23. REMOVE VACUUM PUMP ASSEMBLY

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  24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  26. REMOVE ENGINE MOUNTING BRACKET RH

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  27. REMOVE NO. 2 TIMING CHAIN COVER

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  28. REMOVE CAMSHAFT POSITION SENSOR

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  29. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  30. DISCONNECT WATER INLET HOSE LH

    1. A350428

      Slide the hose clip and disconnect the water inlet hose LH from the water inlet.

  31. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  32. REMOVE TIMING CHAIN COVER OIL SEAL

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  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  34. REMOVE CHAIN TENSIONER SLIPPER

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  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  36. REMOVE CHAIN SUB-ASSEMBLY

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  37. REMOVE CAMSHAFT

    1. A350424C01

      *1

      No. 1 Camshaft Bearing Cap

      *2

      No. 2 Camshaft Bearing Cap

      *3

      No. 3 Camshaft Bearing Cap

      *4

      No. 4 Camshaft Bearing Cap

      Remove the 10 bolts from the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing caps and No. 4 camshaft bearing cap by loosening them in the order shown in the illustration, and then remove the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing caps and No. 4 camshaft bearing cap from the cylinder head sub-assembly.

      Note:

      • Using several steps, uniformly loosen the bolts while keeping the camshaft level.

      • Do not remove the No. 3 camshaft bearing cap.

    2. Remove the camshaft from the cylinder head sub-assembly.