ENGINE UNIT DISASSEMBLY

PROCEDURE

  1. PRECAUTION

    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 contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354E02

      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

  2. REMOVE CAMSHAFT POSITION SENSOR

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  3. REMOVE CRANKSHAFT POSITION SENSOR

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  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  6. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

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  7. REMOVE INJECTOR ASSEMBLY

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  8. REMOVE ENGINE WATER PUMP ASSEMBLY

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  9. REMOVE WATER BY-PASS PIPE

    A318397

    1. Using a 5 mm hexagon socket wrench, remove the bolt and water by-pass pipe from the water inlet housing.

  10. REMOVE WATER INLET

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  11. REMOVE THERMOSTAT

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  12. REMOVE WATER INLET HOUSING

    1. A318398

      Using an E11 "TORX" socket wrench, remove the 5 bolts and water inlet housing.

  13. REMOVE WATER OUTLET

    1. A319677

      Using an E10 "TORX" socket wrench, remove the 3 bolts and water outlet.

    2. Remove the gasket from the water outlet.

  14. REMOVE OIL FILTER SUB-ASSEMBLY

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  15. REMOVE OIL FILTER ASSEMBLY

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  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  17. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  19. SECURE CAMSHAFT AND NO. 2 CAMSHAFT

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  20. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  21. REMOVE NO. 2 TIMING CHAIN GUIDE

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  22. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

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  23. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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

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  25. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  26. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  27. REMOVE CYLINDER HEAD GASKET

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  28. REMOVE CRANKSHAFT PULLEY

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  29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

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  30. REMOVE CLUTCH COVER ASSEMBLY

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  31. REMOVE CLUTCH DISC ASSEMBLY

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  32. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY

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  33. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    1. A316273

      Remove the sealing cap from the timing chain cover plate.

    2. Remove the O-ring from the sealing cap.

    3. A316274N02

      Using SST (B), install SST (A) to position the fuel supply pump assembly. Then remove SST (B).

      SST

      PZ4TB-04967-25

      Note:

      Do not remove SST (A) from the timing chain cover plate until all repair work has been completed.

    4. A316275

      Remove the 4 bolts and fuel supply pump assembly support.

    5. A316276

      Remove the 2 bolts from the fuel supply pump assembly.

    6. A316352C01

      *1

      Central Bolt
      A316277E01

      Loosen the central bolt connection between the fuel supply pump assembly and injection pump drive gear.

      Note:

      • Do not remove SST (A) from the timing chain cover plate.

      • The central bolt is supported on SST (A) until the fuel supply pump assembly is pressed out.

      • Do not remove the central bolt from SST (A) until all repair work has been completed.

    7. Remove the fuel supply pump assembly from the cylinder block.

  34. REMOVE OIL PAN SUB-ASSEMBLY

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  35. REMOVE OIL STRAINER SUB-ASSEMBLY

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  36. REMOVE OIL PUMP WITH VACUUM PUMP ASSEMBLY

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  37. REMOVE REAR ENGINE OIL SEAL

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  38. REMOVE TIMING CHAIN COVER PLATE

    1. A318591

      Using an E8 "TORX" socket wrench, remove the 11 bolts and timing chain cover plate.

  39. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

    1. A319675

      Remove the oil pump drive chain sub-assembly from the crankshaft.

  40. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    1. A319674

      Remove the No. 2 chain sub-assembly from the injection pump drive gear.

  41. REMOVE NO. 2 TIMING CHAIN TENSION ARM

    1. A318592

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

  42. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A319672C01

      *a

      Hexagon Wrench

      Slowly push the plunger deep into the No. 1 chain tensioner assembly and insert a 3.0 mm hexagon wrench into the No. 1 chain tensioner assembly.

    2. A318593

      Using an E8 "TORX" socket wrench, remove the 2 bolts and No. 1 chain tensioner assembly.

  43. REMOVE TIMING CHAIN TENSION ARM

    1. A318594

      Using a T45 "TORX" socket wrench, remove the bolt and timing chain tension arm.

  44. REMOVE TIMING CHAIN GUIDE

    1. A318595

      Using a T45 "TORX" socket wrench, remove the 2 bolts and timing chain guide.

  45. REMOVE INJECTION PUMP DRIVE GEAR

    1. A318596

      Remove the injection pump drive gear and chain sub-assembly.

  46. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY

    1. A318598

      Using an E8 "TORX" socket wrench, remove the bolt and No. 2 oil nozzle sub-assembly.