ENGINE UNIT (w/o DPF) DISASSEMBLY

REMOVE OIL FILLER CAP SUB-ASSEMBLY

REMOVE OIL FILLER CAP GASKET

REMOVE NOZZLE HOLDER SEAL

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

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

REMOVE NOZZLE HOLDER CLAMP NO.1

REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

REMOVE INJECTOR ASSEMBLY

REMOVE CAMSHAFT TIMING PULLEY

REMOVE NO. 2 TIMING BELT COVER

REMOVE CYLINDER BLOCK INSULATOR

REMOVE NO. 2 CAMSHAFT

REMOVE CAMSHAFT

REMOVE CAMSHAFT SETTING OIL SEAL

REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. Uniformly loosen and remove the 18 cylinder head bolts in several steps in the sequence shown in the illustration.

   Note

   Head warpage or cracking could result from removing bolts in an incorrect order.

2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

   Tech Tips

   If the cylinder head is difficult to lift off, use a screwdriver to pry between the cylinder head and block.

   Note

   Do not damage the contact surfaces of the cylinder head and cylinder block.

3. Remove the cylinder head gasket from the cylinder block.

REMOVE WATER PUMP ASSEMBLY

1. Remove the 5 bolts, 2 nuts, water pump and gasket.

REMOVE TIMING GEAR CASE

1. Remove the 14 bolts and 2 nuts.

2. 

   Pry the gear cover in the location shown in the illustration, and remove the gear cover together with the supply pump drive gear.

   Note

   Be careful not to drop the supply pump gear.

3. Remove the O-ring from the timing gear case.

4. 

   Secure the idle sub-gear to the idle gear with a service bolt.

REMOVE INJECTION GEAR

REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

INSPECT BACKLASH OF OIL PUMP GEAR TO CRANKSHAFT TIMING GEAR

1. Using a dial indicator, measure the backlash.

   Standard gear backlash
   0.02 to 0.15 mm (0.0008 to 0.0060 in.)

   Maximum gear backlash
   0.20 mm (0.0079 in.)

   If the gear backlash is greater than the maximum, replace the gears as a set.

INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE

1. Using a dial indicator, measure the thrust clearance.

   Standard thrust clearance
   0.06 to 0.11 mm (0.0024 to 0.0043 in.)

   Maximum thrust clearance
   0.30 mm (0.0118 in.)

   If the thrust clearance is greater than the maximum, replace the thrust plate. If necessary, replace the idle gear and/or idle gear shaft.

REMOVE IDLE GEAR THRUST PLATE

REMOVE NO. 1 IDLE GEAR

1. Turn the sub-gear and align the gear teeth of the idle main gear and sub-gear.

2. Remove the idle gear and sub-gear.

3. 

   Mount the No. 1 idle gear and No. 2 idle subgear in a vise.

   Note

   Be careful not to damage the gears.

4. 

   Text in Illustration

   *1	Service Bolt

   Using SST, turn the No. 1 idle subgear clockwise and remove the service bolt.

   SST

   09960-10010   ( 09962-01000, 09963-00600 )

5. 

   Using snap ring pliers, remove the shaft snap ring.

6. 

   Text in Illustration

   *1	Wave Washer
   *2	No. 1 Idle Sub-Gear
   *3	Idle Gear Spring

   Remove the wave washer, sub-gear and gear spring.

7. 

   Remove the No. 1 idle gear and set it in a vise.

   Note

   Be careful not damage the gear.

8. 

   Using snap ring pliers, remove the shaft snap ring.

9. 

   Text in Illustration

   *1	Wave Washer
   *2	No. 2 Idle Sub-Gear
   *3	Idle Gear Spring

   Remove the wave washer, sub-gear and gear spring.

REMOVE NO. 1 IDLE GEAR SHAFT

1. Remove the idle gear shaft.

INSPECT BACK LASH OF CRANKSHAFT TIMING GEAR TO NO. 1 IDLE GEAR

1. Install the idle gear.

2. Using a dial indicator, measure the backlash.

   Standard gear backlash
   0.02 to 0.15 mm (0.0008 to 0.0060 in.)

   Maximum gear backlash
   0.20 mm (0.0079 in.)

   If the gear backlash is greater than the maximum, replace the gears as a set.

3. Remove the idle gear.

REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

1. Using SST, remove the crankshaft timing gear.

   SST

   09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

INSPECT BACKLASH OF OIL PUMP GEAR TO NO. 1 BALANCE SHAFT

1. Using a dial indicator, measure the backlash.

   Standard gear backlash
   0.02 to 0.15 mm (0.0008 to 0.0060 in.)

   Maximum gear backlash
   0.20 mm (0.0079 in.)

   If the gear backlash is greater than the maximum, replace the gears as a set.

INSPECT BACKLASH OF INJECTION GEAR TO NO. 2 BALANCE SHAFT

1. Install the injection pump with the 2 nuts.

   Torque:

   21 N*m  { 214 kgf*cm, 16 in.*lbf }

2. Using SST, install the injection gear with the nut.

   SST

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

   Torque:

   64 N*m  { 653 kgf*cm, 47 in.*lbf }

3. 

   Using a dial indicator, measure the backlash.

   Standard gear backlash
   0.02 to 0.15 mm (0.0008 to 0.0060 in.)

   Maximum gear backlash
   0.20 mm (0.0079 in.)

   If the gear backlash is greater than the maximum, replace the gears as a set.

INSPECT BACKLASH OF INJECTION GEAR TO NO. 1 IDLE GEAR

1. Install the idle gear without sub gears.

2. Using a dial indicator, measure the backlash.

   Standard gear backlash
   0.02 to 0.15 mm (0.0008 to 0.0060 in.)

   Maximum gear backlash
   0.20 mm (0.0079 in.)

   If the gear backlash is greater than the maximum, replace the gears as a set.

3. Using SST, remove the nut and supply pump gear.

   SST

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

4. Remove the 2 nuts and supply pump.

5. Remove the idle gear.

REMOVE OIL PAN SUB-ASSEMBLY

1. Remove the vinyl tube from the oil pan.

2. Remove the 22 bolts and 2 nuts.

3. 

   Text in Illustration

   *1	Oil Pan Seal Cutter

   Insert the blade of Oil Pan Seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

   Note

   
   

   • Do not use Oil Pan Seal cutter for the timing belt case side and rear oil seal retainer.

   • Be careful not to damage the oil pan flange.

4. w/ Heater:

   Remove the stiffening plate.

REMOVE OIL STRAINER SUB-ASSEMBLY

REMOVE TIMING GEAR CASE ASSEMBLY

1. Remove the union bolt and 8 bolts.

2. 

   Text in Illustration

   *1	Protective Tape

   Pry the gear case in the location shown in the illustration, and remove the gear case.

3. 

   Remove the rotor and gasket.

4. 

   Text in Illustration

   *1

   O-Ring

   Remove the 2 O-rings.

INSPECT NO. 1 BALANCESHAFT SUB-ASSEMBLY

1. Using a dial indicator, measure the thrust clearance by moving the balance shaft back and forth.

   Standard thrust clearance
   0.065 to 0.140 mm (0.0026 to 0.0055 in.)

   Maximum thrust clearance
   0.25 mm (0.0098 in.)

   If the thrust clearance is greater than the maximum, replace the balance shaft thrust washer.

   Tech Tips

   After replacement, if the thrust clearance is still greater than the maximum, replace the balance shaft.

REMOVE NO. 1 BALANCESHAFT SUB-ASSEMBLY

1. Remove the 2 bolts and balance shaft.

REMOVE NO. 1 BALANCESHAFT DRIVEN GEAR

1. Mount the balance shaft between aluminium plates in a vise.

   Note

   Be careful not to damage the balance shaft.

2. Remove the bolt, balance shaft driven gear and balance shaft thrust washer.

INSPECT NO. 2 BALANCESHAFT SUB-ASSEMBLY

1. Using a dial indicator, measure the thrust clearance by moving the balance shaft back and forth.

   Standard thrust clearance
   0.065 to 0.140 mm (0.0026 to 0.0055 in.)

   Maximum thrust clearance
   0.25 mm (0.0098 in.)

   If the thrust clearance is greater than the maximum, replace the balance shaft thrust washer.

   Tech Tips

   After replacement, if the thrust clearance is still greater than the maximum, replace the balance shaft.

REMOVE NO. 2 BALANCESHAFT SUB-ASSEMBLY

1. Remove the 2 bolts and balance shaft.

REMOVE NO. 2 BALANCESHAFT DRIVEN GEAR

1. Mount the balance shaft between aluminium plates in a vise.

   Note

   Be careful not to damage the balance shaft.

2. Remove the bolt, balance shaft driven gear and balance shaft thrust washer.

REMOVE REAR ENGINE OIL SEAL RETAINER

1. Remove the 5 bolts.

2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and cylinder block.

REMOVE CYLINDER BLOCK OIL ORIFICE

INSPECT CONNECTING ROD THRUST CLEARANCE

1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

   Standard thrust clearance
   0.100 to 0.300 mm (0.0039 to 0.0118 in.)

   Maximum thrust clearance
   0.40 mm (0.0157 in.)

   If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

REMOVE PISTON AND CONNECTING ROD

1. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

   Text in Illustration

   *a	Alignment marks

2. Remove the 2 connecting rod cap bolts.

3. 

   Using the 2 removed connecting rod bolts, pry the connecting rod cap back and forth, and remove the connecting cap.

   Tech Tips

   Keep the lower bearing inserted into the connecting rod cap.

4. Clean the crank pin and bearing.

5. Check the crank pin and bearing for pitting and scratches.

   If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

6. 

   Using a ridge reamer, remove all the carbon from the top of the cylinder.

7. Push out the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

   Tech Tips

   
   

   • Keep the bearings, connecting rod and cap together.

   • Be sure to organize the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

INSPECT CONNECTING ROD OIL CLEARANCE

1. 

   Text in Illustration

   *1	Plastigage

   Lay a strip of Plastigage across the crank pin.

2. 

   Text in Illustration

   *a	Alignment marks

   Install the connecting rod cap with the 2 bolts.

   Note

   Do not turn the crankshaft.

   Tech Tips

   
   

   • The connecting rod cap bolts are tightened in 2 progressive steps.

   • If any connecting rod bolt is broken or deformed, replace it.

   
   

   1. Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

   2. Install and alternately tighten the bolts of the connecting rod cap several passes.

      Torque:

      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolt.

   3. 

      Text in Illustration

      *a	Painted Mark
      *b	Front

      Mark the front of the connecting rod cap bolts with paint.

   4. Retighten the connecting rod cap bolts 90° as shown.

   5. Check that the painted mark is now at a 90 ° angle to the front.

3. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

4. Remove the 2 bolts, connecting rod cap and lower bearing.

5. 

   Text in Illustration

   *1	Plastigage

   

   Text in Illustration

   *a	Mark 1, 2 or 3
   *b	Mark 2, 3, 4, 5 or 6
   *c	No. 1
   *d	No. 2
   *e	No. 3
   *f	No. 4

   Measure the Plastigage at its widest point.

   Standard oil clearance
   Use standard bearing
   0.036 to 0.054 mm (0.0014 to 0.0021 in.)
   Use U/S 0.25 or U/S 0.50 bearing
   0.037 to 0.077 mm (0.0015 to 0.0030 in.)

   Maximum oil clearance
   0.10 mm (0.0039 in.)

   If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

   Tech Tips

   If using a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the crankshaft and connecting rod, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

   Bearing size
   Item Number Mark Connecting rod cap 1 2 3 Crankshaft 1 2 3 1 2 3 1 2 3 Use bearing 2 3 4 3 4 5 4 5 6

   EXAMPLE:

   Connecting rod cap "2" + Crankshaft "3" =

   Total number 5 (Use bearing "5")

   Reference
   Standard connecting rod big end inside diameter
   Mark Diameter 1 62.014 to 62.020 mm (2.4415 to 2.4417 in.) 2 62.020 to 62.026 mm (2.4417 to 2.4420 in.) 3 62.026 to 62.032 mm (2.4420 to 2.4422 in.)
   Standard crankshaft pin diameter
   Mark Diameter 1 58.994 to 59.000 mm (2.3226 to 2.3228 in.) 2 58.988 to 58.994 mm (2.3224 to 2.3226 in.) 3 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
   Standard sized bearing center wall thickness
   Mark Diameter 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) 2 1.489 to 1.492 mm (0.0586 to 0.0587 in.) 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) 4 1.495 to 1.498 mm (0.0589 to 0.0590 in.) 5 1.498 to 1.501 mm (0.0590 to 0.0591 in.)

6. Completely remove the Plastigage.

INSPECT CRANKSHAFT THRUST CLEARANCE

1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

   Standard thrust clearance
   0.040 to 0.240 mm (0.0016 to 0.0094 in.)

   Maximum thrust clearance
   0.30 mm (0.0118 in.)

   If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

   Standard thrust washer thickness
   STD 2.430 to 2.480 mm (0.0957 to 0.0976 in.) O/S 0.125 2.555 to 2.605 mm (0.1006 to 0.1026 in.) O/S 0.25 2.680 to 2.730 mm (0.1055 to 0.1074 in.)

INSPECT CRANKSHAFT OIL CLEARANCE

REMOVE PISTON PIN

1. Check the fit between the piston and piston pin.

   
   

   1. Try to move the piston back and forth on the piston pin.

      If any movement is felt, replace the piston and pin as a set.

2. 

   Using a piston ring expander, remove the 2 compression rings.

   Tech Tips

   Be sure to organize the removed piston rings in such a way that they can be reinstalled exactly as before.

3. Remove the oil ring by hand.

4. 

   Disconnect the connecting rod from the piston.

   
   

   1. Using a small screwdriver, pry off the 2 snap rings from the piston.

   2. 

      Gradually heat the piston to approximately 80°C (176°F).

   3. 

      Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

      Tech Tips

      
      

      • The piston and pin are a matched set.

      • Be sure to organize the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

REMOVE CRANKSHAFT

1. Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several passes, in the sequence shown.

2. 

   Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and remove the crankshaft bearing caps, lower crankshaft bearings and lower thrust washers (No. 3 crankshaft bearing cap only).

   Tech Tips

   
   

   • Keep the lower bearing and crankshaft bearings cap together.

   • Be sure to organize the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

3. Lift out the crankshaft.

4. Remove the upper bearings and upper thrust washers from the cylinder block.

   Tech Tips

   Arrange the main bearing caps, bearings and thrust washers in the correct order.

REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

1. Remove the 4 check valves and oil nozzles.

REMOVE PLUG

1. Remove the plug from the cylinder block.

REMOVE PLATE PLUG

1. Remove the bolt, plate plug and O-ring.

REMOVE RING PIN

1. 

   Text in Illustration

   *a	Cylinder Head Side

   Remove the 2 ring pins as shown in the illustration.

REMOVE STRAIGHT PIN

1. 

   Text in Illustration

   *a	Front Side
   *b	Rear Side

   Remove the 6 straight pins as shown in the illustration.

REMOVE STUD BOLT

REMOVE TIGHT PLUG