ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

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

  • A004OHTE01

    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

PROCEDURE


  1. REMOVE CAMSHAFT POSITION SENSOR

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  2. REMOVE CRANKSHAFT POSITION SENSOR

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  3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  4. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  5. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

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  6. REMOVE INJECTOR ASSEMBLY

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  7. REMOVE ENGINE WATER PUMP ASSEMBLY

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  8. REMOVE WATER BY-PASS PIPE


    1. A004R6H

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

  9. REMOVE WATER INLET

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  10. REMOVE THERMOSTAT

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  11. REMOVE WATER INLET HOUSING


    1. A004PR5

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

  12. REMOVE WATER OUTLET


    1. A004R56

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

    2. Remove the gasket from the water outlet.

  13. REMOVE OIL FILTER SUB-ASSEMBLY

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  14. REMOVE OIL FILTER ASSEMBLY

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  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  16. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. HOLDING CAMSHAFT AND NO. 2 CAMSHAFT

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  19. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  20. REMOVE NO. 2 TIMING CHAIN GUIDE

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  21. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

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  22. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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

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  24. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  25. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  26. REMOVE CYLINDER HEAD GASKET


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

  27. REMOVE CRANKSHAFT PULLEY

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

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  29. REMOVE CLUTCH COVER ASSEMBLY

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  30. REMOVE CLUTCH DISC ASSEMBLY

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  31. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY

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  32. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A004RAJ

      Remove the sealing cap from the timing chain cover plate.

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

    3. A004OFZE01

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

      SST
      PZ4TB-04967-25

      Note

      SST A remains in the timing chain cover plate until the end of the repair work.

    4. A004R5V

      Remove the 4 bolts and fuel supply pump assembly support.

    5. A004MKI

      Remove the 2 bolts from the fuel supply pump assembly.

    6. A004NJLE01
      Text in Illustration
      *1 Central Bolt

      Remove the screw connection between the fuel supply pump assembly and injection pump drive gear.

      Note


      • SST A remains in the timing chain cover plate.

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

      • A004TX3E05

        The central bolt remains inside SST A attached to the injection pump drive gear.

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

  33. REMOVE OIL PAN SUB-ASSEMBLY

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  34. REMOVE OIL STRAINER SUB-ASSEMBLY

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  35. REMOVE OIL PUMP WITH VACUUM PUMP ASSEMBLY

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  36. REMOVE REAR ENGINE OIL SEAL

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  37. REMOVE TIMING CHAIN COVER PLATE


    1. A004PR0

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

  38. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. A004QDY

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

  39. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A004NQR

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

  40. REMOVE NO. 2 TIMING CHAIN TENSION ARM


    1. A004U7S

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

  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A004PIAE03
      Text in Illustration
      *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. A004N0M

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

  42. REMOVE TIMING CHAIN TENSION ARM


    1. A004MKJ

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

  43. REMOVE TIMING CHAIN GUIDE


    1. A004PCD

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

  44. REMOVE INJECTION PUMP DRIVE GEAR


    1. A004OVA

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

  45. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A004R1P

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