ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A004QAIE04
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    2. Remove the bolt and No. 2 nozzle leakage pipe.

  2. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A004T4L

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  3. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A004PC6

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

  4. REMOVE INJECTOR ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A004OQS

      Remove the bolt and sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A004SMS

      Remove the clip and disconnect the sensor harness.

    2. Remove the 2 bolts and sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A004QWQE02

      Using SST, remove the sensor and gasket.

      SST
      09817-33190

  8. REMOVE WATER PUMP ASSEMBLY

    Click here

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  10. REMOVE OIL COOLER ASSEMBLY

    Click here

  11. REMOVE NO. 1 OIL COOLER BRACKET

    Click here

  12. REMOVE ENGINE OIL LEVEL SENSOR


    1. A004PSO

      Remove the 4 bolts and sensor.

  13. REMOVE WATER INLET HOUSING


    1. A004SM4

      Remove the 3 nuts, gasket and water inlet housing.

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  17. REMOVE OIL FILTER ELEMENT

    Click here

  18. REMOVE OIL FILTER BRACKET

    Click here

  19. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  20. REMOVE CRANKSHAFT PULLEY


    1. Set the No. 1 piston to TDC/compression.


      1. A004NO4E02
        Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark

        Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.

    2. A004U7YE01
      Text in Illustration
      *1 Matchmark
      *2 Timing Mark

      Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/compression).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tech Tips

      The timing chain has 2 colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A004RSAE03

      Turn the crankshaft by approximately 90° in the direction of engine revolution from the point where the No. 1 piston is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

    5. A004SJ5E02

      Using SST, remove the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A004QMHE01

      Using SST, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  22. REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A004OL3E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner.

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )
    3. A004Q6O

      Remove the 2 bolts and No. 1 chain tensioner.

  24. REMOVE CHAIN TENSIONER SLIPPER

    A004THU

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A004TDT

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

  26. REMOVE CAMSHAFT TIMING SPROCKET


    1. A004PNF

      Remove the 4 bolts from the sprocket while holding the hexagonal portion of the No. 2 camshaft with a wrench.

    2. Remove the camshaft timing sprocket and chain.

  27. REMOVE OIL PUMP DRIVE GEAR


    1. A004TI2

      Remove the oil pump drive gear from the crankshaft.

  28. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A004SWQ

      Remove the crankshaft timing sprocket.

  29. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. A004MRY

      Remove the 2 keys from the crankshaft.

  30. REMOVE CAMSHAFT

    Click here

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

    Click here

  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  33. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  34. REMOVE CYLINDER HEAD GASKET

  35. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A004P2PE07
      Text in Illustration
      *1 Cut Position

      Using a knife, cut off the lip of the rear crankshaft oil seal.

    2. Using a screwdriver, pry out the rear crankshaft oil seal.

      Note

      Be careful not to damage the crankshaft.

  36. REMOVE OIL BAFFLE PLATE


    1. A004ORS

      Remove the 2 bolts and oil baffle plate.

  37. REMOVE ENGINE BALANCER ASSEMBLY


    1. A004S97E03
      Text in Illustration
      *1 Service Bolt

      Align the timing marks (1 dot mark each) of the drive and driven gears by turning the crankshaft with a wrench.

    2. Put matchmarks on the drive gear and driven gear.

    3. Install a service bolt.

      Recommended Service Bolt
      Item Specified Condition
      Thread diameter 6 mm (0.236 in.)
      Thread pitch 1 mm (0.0394 in.)
      Bolt length 16 to 18 mm (0.630 to 0.709 in.)
      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

      Tech Tips

      When removing the balancer, make sure that the torsional spring force of the sub gear has been eliminated by the installation of the service bolt.

    4. A004RHGE03

      Uniformly loosen the 8 bolts in several steps, in the sequence shown in the illustration.

    5. Remove the engine balancer.

  38. REMOVE CYLINDER BLOCK DRAIN COCK PLUG


    1. A004Q6X

      Remove the cylinder block drain cock plug from the cylinder block.