Camshaft (W/O Dpf) Removal

After replacing fuel injector(s) with new one(s), input compensation code(s) of fuel injector(s) into ECM as follows:

HINT:

1. Each fuel injector has different fuel injection characteristics. In order to optimize the fuel injections, the ECM uses the compensation codes to balance the different fuel injections between each fuel injector.
   
2. When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set. This is to inform you that registration of a fuel injector compensation code(s) is/are required. Manually clear the DTC upon completion of the compensation code registration.
   

1. Input the compensation code(s), which is/are imprinted on the head portion(s) of the new fuel injector(s), into the intelligent tester.
   

2. Input the new compensation code(s) into the ECM using the tester.
   

3. Turn the tester off and turn the ignition switch off.
   

4. Wait for at least 30 seconds.
   

5. Turn the ignition switch to ON and turn the tester on.
   

6. Clear DTC P1601 stored in the ECM using the tester (Click here).
   

Register compensation code.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

   NOTICE:

   Do not start the engine.

3. Turn the tester on.
   





4. Enter the following menus: Powertrain / Engine / Utility / Injector Compensation.
   

5. Press Next.
   





6. Press Next again to proceed.
   





7. Select "Set Compensation Code".
   

8. Press Next.
   





9. Select the number of the cylinder corresponding to the fuel injector compensation code that you want to read.
   

10. Press Next.
    





11. Register compensation code.
    

    1. Press Input.
       
    
    
    2. Manually input the cylinder compensation code using the keyboard on the tester screen. The code is a 30 digit, alphanumeric value printed on the injector head portion.
       

       HINT:

       Each fuel injector compensation code is unique. The compensation code for each selected cylinder must be input into the tester correctly.

    3. Confirm that the compensation code for the selected cylinder is correct, and then press OK.
       




12. Check that the compensation code displayed on the screen is correct by comparing it with the 30 digit alphanumeric value on the head portion of the fuel injector.
    

    NOTICE:

    If an incorrect fuel injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

    HINT:

    1. If a wrong compensation code is input or read, return to the Input Value screen by pressing Input.
       
    2. The saving process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and repeat this operation.
       

13. Press Next to register the compensation code in the ECM.
    

    HINT:

    1. If the registration process fails, the compensation code may be incorrect. Check the compensation code again.
       
    2. If the input compensation code fails to register even though it is input correctly, there may be a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and restart this operation.
       




14. If you want to continue with other compensation code registrations, press Next. To finish the registration, press Cancel.
    

15. Turn the ignition switch off and then turn the tester off.
    

16. Wait for at least 30 seconds.
    

17. Turn the ignition switch to ON and then turn the tester on.
    

18. Clear DTC P1601 stored in the ECM using the tester (Click here).
    

Remove the 2 bolts and No. 2 engine under cover seal from the No. 2 engine under cover.

Remove the oil filler cap.

Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

Install a new gasket and the oil pan drain plug.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Remove the 3 bolts and screw.

Loosen the clip and remove the front fender splash shield LH.

Remove the 3 bolts and 2 screws.

Loosen the clip and remove the front fender splash shield RH.

Remove the 10 bolts and No. 1 engine under cover.

Loosen the radiator drain cock plug.

Remove the radiator reservoir cap to drain the coolant in the radiator.

Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

Tighten the radiator drain cock plug by hand.

Tighten the oil filter bracket drain cock plug.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Remove the 7 clips and upper radiator support seal.

Disconnect the 4 wire harness clamps.

Remove the 2 nuts and No. 3 engine room wire.

Remove the 2 nuts and No. 1 engine cover.

Loosen the hose clamp.

Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

Detach the 4 clamps and remove the air cleaner cap.

Loosen the hose clamp and remove the No. 1 air cleaner hose.

w/ Viscous Heater:
Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

w/o Viscous Heater:
Disconnect the connector from the water temperature sensor.

Using a clip remover, detach the 3 wire harness clamps.

Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

Loosen the lock nut and turn the bolt counterclockwise.

Remove the V-ribbed belt.

Remove the bolt, cover, No. 1 idler pulley and collar.

Remove the nut and No. 3 idler pulley.

Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

Remove the 3 clips and front fender apron seal front RH.

Remove the 4 clips and front fender apron seal rear RH.

w/o KDSS:
Remove the 4 clips and front fender apron seal front LH.

w/ KDSS:
Remove the 3 clips and front fender apron seal front LH.

Remove the 4 clips and front fender apron seal rear LH.

Insert a screwdriver between the reservoir and oil reservoir bracket, push the claw, and then disconnect the reservoir by pulling it upwards.

Remove the 2 bolts and bracket.

Disconnect the 2 hoses.

Remove the 3 bolts and radiator reservoir.

Remove the 2 nuts and vane pump.

Remove the O-ring from the vane pump.

Disconnect the inlet and outlet No. 1 oil cooler hose.

Disconnect the inlet No. 2 and No. 3 oil cooler hoses.

Disconnect the inlet No. 4 oil cooler hose.

Remove the 2 bolts and transmission oil cooler tube.

Loosen the 4 nuts holding the fluid coupling fan.

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid coupling fan.

Using a clip remover, detach the 3 clips and remove the fender main seal.

Remove the nut, wiper arm and blade.

Remove the nut, wiper arm and blade.

Using a clip remover, detach the 12 clips, 4 clamps and remove the hood to cowl top seal.

Remove the washer hose.

Remove the 2 clips.

Detach the 17 claws and remove the cowl top ventilator louver sub-assembly.

Loosen the No. 1 air hose clamp.

Loosen the No. 2 air hose clamp.

Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

Remove the 6 nuts, 2 bolts and intercooler.

Remove the 2 gaskets from the air tube LH and RH.

Loosen the No. 1 air hose clamp.

Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

Remove the 3 nuts, bolt and No. 1 cool air inlet.

Remove the gasket from the air tube RH.

Loosen the No. 2 air hose clamp.

Remove the 3 nuts, bolt and No. 2 cool air inlet.

Remove the gasket from the air tube LH.

Loosen the hose clamp and remove the No. 1 air hose.

Loosen the hose clamp and remove the No. 2 air hose.

Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

Disconnect the ventilation hose from the cylinder head cover RH.

Remove the 2 bolts and No. 2 engine oil level dipstick guide.

Remove the O-ring from the No. 2 engine oil level dipstick guide.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

NOTICE:

1. Do not bend or damage the flexible hose tubes.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.
   

Remove the 2 clips.

Remove the bolt and clutch hose.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

NOTICE:

1. Do not bend or damage the flexible hose tube.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.
   

Remove the 2 bolts and tube connector to flexible hose tube.

Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

Disconnect the wire harness from the clamp.

Remove the nut and ground wire.

Remove the bolt and disconnect the wire harness bracket.

Loosen the hose clamp and remove the bolt and No. 3 air tube.

Loosen the hose clamp.

Remove the bolt and No. 1 air cleaner pipe.

Remove the bolt and disconnect the suction hose.

Loosen the hose clamp and remove the bolt and No. 4 air tube.

Disconnect the ventilation hose from the oil separator.

Loosen the hose clamp.

Remove the bolt and No. 2 air cleaner pipe.

Disconnect the connector and detach the clamp.

Using pliers, grip the claws of the clips and slide the 2 clips.

Disconnect the 2 heater hoses.

Remove the 2 bolts and heater assembly.

Remove the bolt and No. 1 idler pulley bracket.

w/ EGR System:

1. Remove the 2 bolts and nut.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

2. w/ DPF:
   Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

3. w/o DPF:
   Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.
   

w/o EGR System:

1. Remove the 2 bolts and nut.
   

2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

w/ DPF:

w/o DPF:

LH Side:

1. Disconnect the 4 connectors from the injector driver.
   

2. Remove the 4 connectors and detach the wire harness holder from the relay block.
   

3. Remove the bolt and disconnect the ground wire.
   

4. Disconnect the wire harness from the wire harness clamp holder.
   





5. Remove the bolt and disconnect the ground wire from the body panel.
   

6. Using a clip remover, detach the ground wire clamp labeled A from the relay block side.
   

7. Disconnect the wire harness from the wire harness clamp holder labeled B.
   





8. Disconnect the 4 connectors.
   

9. Using a clip remover, detach the 3 wire harness clamps.
   





10. Disconnect the 2 connectors.
    

11. Using a clip remover, detach the 3 wire harness clamps.
    





12. Disconnect the 8 connectors.
    

13. Remove the 2 bolts labeled A and disconnect the engine wire protector.
    

14. Remove the bolt labeled B and engine wire harness bracket.
    

15. for RHD:
    Disconnect the wire harness from the wire harness clamp holder labeled C.
    

RH Side:

1. Disconnect the 4 connectors.
   

2. Using a clip remover, detach the 5 wire harness clamps.
   





3. Disconnect the 7 connectors.
   

4. Using a clip remover, detach the wire harness clamp.
   

5. Remove the 3 bolts labeled A and disconnect the wire harness protector.
   

6. Remove the bolt labeled B and wire harness bracket.
   

7. Remove the nut labeled C and glow plug wire harness.
   

for LHD:

1. Disconnect the 4 connectors, and detach the wire harness tab labeled A from the relay block.
   

2. Disconnect the ECM connector.
   

3. Disconnect the wire harness from the wire harness clamp holder.
   

for RHD:

1. Disconnect the wire harness from the wire harness clamp holder.
   





2. Disconnect the 4 connectors, and detach the wire harness tab labeled A from the relay block.
   

3. Disconnect the ECM connector.
   

4. Disconnect the wire harness from the wire harness clamp holder.
   

Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

Remove the bolt and No. 2 injection pipe clamp.

Remove the union bolt and gasket.

Remove the bolt, nut and No. 2 fuel pipe.

w/ EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.
   

3. Remove the No. 6 injection pipe.
   

w/o EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the nut and No. 2 injection pipe clamp.
   

3. Remove the bolt and No. 6 injection pipe.
   

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the 2 bolts and common rail.

NOTICE:

1. Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.
   
2. w/ DPF:
   Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.
   

w/ DPF:

1. Remove the bolt and No. 2 injection pipe clamp.
   

2. Disconnect the fuel hose.
   

3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.
   

w/o DPF:

1. Disconnect the 2 hoses from the fuel pipe.
   

2. Remove the bolt and fuel filter to injection pump fuel pipe.
   

Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the bolt, cover, No. 2 idler pulley and collar.

Remove the 3 bolts and idler pulley bracket.

Disconnect the 2 vacuum hoses.

Remove the bolt and vacuum switching valve.

w/ Intercooler:
Disconnect the 2 vacuum hoses.

Remove the 3 bolts and vacuum transmitting pipe.

Remove the 3 bolts and vacuum pump.

Remove the 2 O-rings.

Remove the 3 bolts and cylinder head cover silencer.

Remove the 3 bolts and cylinder head cover silencer.

Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

HINT:

Tape the screwdriver tip before use.

Remove the 18 bolts, cylinder head cover and gasket.

Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

HINT:

Tape the screwdriver tip before use.

Remove the 3 bolts, oil separator and gasket.

Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

HINT:

Tape the screwdriver tip before use.

Remove the 17 bolts, cylinder head cover and gasket.

Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

HINT:

Tape the screwdriver tip before use.

Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

Text in Illustration

Union Bolt

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

Text in Illustration

Union Bolt

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

Rotate the crankshaft clockwise, and align the No. 1 camshaft timing sprocket arrow with the cylinder head upper surface.

Using a 10 mm hexagon wrench, remove the taper screw plug.

Fix the No. 1 chain tensioner in place.

1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.
   

2. Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.
   





3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.
   

   NOTICE:

   Do not drop the hexagon wrench into the engine.

   
   
   
   
   
   

Using SST, hold the pump drive shaft gear.

SST

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

Remove the 2 bolts.

Rotate the crankshaft clockwise 360° so that the No. 1 camshaft timing sprocket arrow points at the No. 1 camshaft center.

NOTICE:

Do not rotate the crankshaft counterclockwise in order to align the sprocket arrow and camshaft center.

Place matchmarks on the No. 1 timing chain and No. 1 camshaft timing sprocket.

Place matchmarks on the No. 1 and No. 2 camshaft gears.

Using SST, hold the pump drive shaft gear.

SST

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

Remove the 2 bolts and pump drive shaft gear.

Disconnect the No. 1 timing chain and No. 1 camshaft timing sprocket from the No. 2 camshaft.

NOTICE:

1. Do not remove the No. 1 camshaft timing sprocket from the No. 1 timing chain.
   
2. Do not rotate the crankshaft until the No. 1 timing chain and No. 1 camshaft timing sprocket are connected to the No. 2 camshaft.
   

HINT:

If fixing the No. 1 camshaft timing sprocket in place, pass a rope or equivalent through one of the No. 1 camshaft timing sprocket holes and tie the sprocket and chain together.

Turn the No. 1 camshaft clockwise so that the bolt is easier to install.

Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

NOTICE:

Do not drop the bolt into the engine.

HINT:

If it is difficult to install the bolt, rotate the camshaft so that the bolt is easier to install.

Loosen the 2 union bolts.

Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the No. 1 and No. 2 camshafts.

Rotate the crankshaft clockwise, and align the No. 2 camshaft timing sprocket arrow with the cylinder head upper surface.

Using a 10 mm hexagon wrench, remove the taper screw plug.

Fix the No. 2 chain tensioner in place.

1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.
   

2. Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.
   





3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.
   

   NOTICE:

   Do not drop the hexagon wrench into the engine.

   
   
   
   
   
   

Using SST, hold the No. 2 camshaft timing sprocket.

SST

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

Remove the 2 bolts.

Rotate the crankshaft clockwise 360° so that the No. 2 camshaft timing sprocket arrow points at the No. 4 camshaft center.

Place matchmarks on the No. 2 timing chain and No. 2 camshaft timing sprocket.

Place matchmarks on the No. 3 and No. 4 camshaft gears.

Using SST, hold the No. 2 camshaft timing sprocket.

SST

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

Remove the 2 bolts, and disconnect the No. 2 timing chain and No. 2 camshaft timing sprocket from the No. 3 camshaft.

NOTICE:

1. Do not remove the No. 2 camshaft timing sprocket from the No. 2 timing chain.
   
2. Do not rotate the crankshaft until the No. 2 timing chain and No. 2 camshaft timing sprocket are connected to the No. 3 camshaft.
   

HINT:

If fixing the No. 2 camshaft timing sprocket in place, pass a rope or equivalent through one of the No. 2 camshaft timing sprocket holes and tie the sprocket and chain together.

Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

NOTICE:

Do not drop the bolt into the chain cover.

HINT:

If it is difficult to install the bolt, rotate the camshaft so that the bolt is easier to install.

Loosen the 2 union bolts.

Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

Remove the 2 union bolts and No. 3 and No. 4 oil feed pipes.

Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the No. 3 and No. 4 camshafts.