CAMSHAFT > REMOVAL

for Preparation Click here



1. REMOVE ENGINE ASSEMBLY

  1. Remove the engine assembly (Click here).



2. REMOVE GENERATOR ASSEMBLY


A198401

  1. Remove the 2 bolts, nut and generator.



3. REMOVE GENERATOR BRACKET


A198402

  1. Remove the bolt and the generator bracket.



4. REMOVE EGR WITH COOLER PIPE ASSEMBLY


A202801

  1. Disconnect the vacuum transmitting hose.

  1. Disconnect the No. 1 vacuum transmitting hose.



    A202804

  1. Disconnect the 2 vacuum hoses and No. 1 oil hose.

  1. Disconnect the No. 2 oil cooler hose.

  1. Disconnect the No. 2 water by-pass hose.



    A202805

  1. Remove the 4 bolts, 2 nuts and the EGR with cooler pipe assembly.

  1. Remove the 2 gaskets from the cylinder head and the electric EGR control valve.



5. REMOVE NO. 1 EGR COOLER BRACKET


A202806

  1. Disconnect the vacuum hose.

  1. Remove the 2 bolts and the No. 1 EGR cooler bracket.



6. REMOVE HARNESS BRACKET


A198412

  1. Disconnect the vacuum hose from the vacuum pump.

  1. Remove the bolt and harness bracket.



7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


A202808

  1. Disconnect the No. 4 water by-pass hose.

  1. Disconnect the No. 3 water by-pass hose.

  1. Remove the 2 bolts and the electric EGR control valve.

  1. Remove the gasket from the intake air connector.



8. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY


A202770

  1. Remove the 2 bolts, 2 nuts and the intake air connector with the diesel throttle body.

  1. Remove the gasket from the cylinder head.



9. REMOVE NO. 2 INJECTION PIPE CLAMP


    A202913

  1. Remove the nut and both sides of the No. 2 injection pipe clamp.



10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    A202916

  1. Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), separate the union nut from the supply pump first.

  1. Then remove the union nut from the common rail, and remove the fuel inlet pipe.

  1. After removing the fuel inlet pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.



11. REMOVE NOZZLE LEAKAGE PIPE SET CLAMP


A198350

  1. Remove the 3 nozzle leakage pipe set clamps.



12. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


A194598

  1. Remove the retainer spring disconnect the nozzle leakage pipe.



    A202905E01

  1. Pull up the lock bush as shown in the illustration and remove the nozzle leakage pipe.
    Text in Illustration 
    *1
    		Lock Bush

    NOTICE:
    Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.



13. DISCONNECT NO. 2 FUEL HOSE


A194600

  1. Disconnect the No. 2 fuel hose.



14. REMOVE SUPPLY PUMP ASSEMBLY


A196505

  1. Remove the 3 bolts and supply pump.



    A202920

  1. Remove the O-ring.



15. REMOVE SUPPLY PUMP DRIVE COUPLING


    A202919

  1. Remove the supply pump driving coupling.

    NOTICE:
    When removing the supply pump, make sure that the drive coupling does not fall off, as it can be easily removed. If the drive coupling falls off, replace it with a new one.



16. REMOVE NO. 2 OIL COOLER HOSE


    A204118

  1. Remove the hose clamp.



    A202765

  1. Disconnect the 2 clamps and remove the No. 2 oil cooler hose.



17. REMOVE NO. 4 WATER BY-PASS HOSE


A202771

  1. Remove the No. 4 water by-pass hose.



18. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


A194564

  1. Disconnect the oil cooler hose.



    A205777

  1. Disconnect the water by-pass hose.



    A205776

  1. Remove the 2 bolts and the water by-pass pipe.

  1. Remove the O-ring from the water by-pass pipe.



19. REMOVE ENGINE OIL LEVEL DIPSTICK


20. REMOVE OIL LEVEL DIPSTICK GUIDE


A198410

  1. Remove the 2 bolts and the oil level dipstick guide.

  1. Remove the O-ring from the oil level dipstick guide.



21. REMOVE NO. 2 CYLINDER HEAD COVER


A204121

  1. Remove the 2 bolts and the 2 harness brackets.



    A204126

  1. Remove the No. 2 cylinder head cover.



22. REMOVE CAMSHAFT POSITION SENSOR


A208059

  1. Remove the bolt and harness bracket.

  1. Remove the bolt and camshaft position sensor.



23. REMOVE VACUUM PUMP ASSEMBLY


A204610

  1. Remove the 2 bolts and vacuum pump.

  1. Remove the 2 O-rings from the vacuum pump.



24. REMOVE IDLER PULLEY SUB-ASSEMBLY


A198403

  1. Remove the bolt and idler pulley.



25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


A204606

  1. Remove the 2 bolts and the V-ribbed belt tensioner.



26. REMOVE HARNESS BRACKET (w/o Air Conditioning System)


A202764

  1. Remove the bolt and harness bracket.



27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    A198344

  1. Remove the 12 bolts and the cylinder head cover.

  1. Remove the cylinder head cover gasket from the cylinder head cover.



28. REMOVE ENGINE MOUNTING BRACKET RH


    A198404

  1. Remove the 4 bolts and the engine mounting bracket.



29. REMOVE NO. 2 TIMING CHAIN COVER


A198405

  1. Remove the clip and the No. 2 timing chain cover.



30. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY


A204630E01

  1. Using SST, hold the crankshaft damper and loosen the crankshaft bolt.

    SST
    09213-58014  
    09330-00021  



    A204632E01

  1. Using SST, remove the crankshaft pulley bolt and the crankshaft pulley.

    SST
    09950-30012   (09951-03010, 09953-03010, 09956-03020)



31. DISCONNECT WATER INLET HOSE LH


A202793

  1. Disconnect the water inlet hose LH.



32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    A198332

  1. Remove the 20 bolts and the 2 nuts.



    A202763E01

  1. Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover by prying between the cylinder head and cylinder block.
    Text in Illustration 
    *1
    		Protective Tape

    NOTICE:
    Do not damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.



33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
Do not rotate the crankshaft with the chain tensioner removed.



    A198526E02

  1. Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.
    Text in Illustration 
    *1
    		Plunger
    *2
    		Groove
    *3
    		Hole



    A198527

  1. Remove the 2 bolts and the No. 1 chain tensioner.



34. REMOVE CHAIN TENSIONER SLIPPER


    A198525

  1. Remove the chain tensioner.



35. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    A198524

  1. Remove the 2 bolts and the No. 1 chain vibration damper.



36. REMOVE CHAIN SUB-ASSEMBLY


    A198523E01

  1. Using SST, hold the camshaft timing sprocket.

    SST
    09960-10010   (09962-01000, 09963-01000)

  1. Remove the 3 bolts and the camshaft timing sprocket.



    A194558

  1. Remove the camshaft timing sprocket, crankshaft timing sprocket and chain together.



37. REMOVE CAMSHAFT


A200011E02
Text in Illustration 
*1
No. 3 Camshaft Bearing Cap

  1. Remove the 10 bolts from the camshaft bearing caps by loosening them in the sequence shown in the illustration, and then remove the 5 camshaft bearing caps.

  1. Remove the camshaft.

    NOTICE:
    1. Using several steps, uniformly loosen the bolts while keeping the camshaft level.
    2. Do not remove the No. 3 camshaft bearing cap.