ENGINE UNIT DISASSEMBLY


  1. REMOVE NO. 1 ENGINE HANGER


    1. A003DLV

      Remove the 2 bolts and No. 1 engine hanger from the cylinder head sub-assembly.

  2. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A003BPP

      Remove the No. 2 cylinder block insulator from the front No. 1 engine mounting bracket LH.

  3. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A003G0X

      Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.

  4. REMOVE NO. 3 CYLINDER BLOCK INSULATOR


    1. A003ADT

      Remove the No. 3 cylinder block insulator from the cylinder block sub-assembly.

  5. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. A003H43

      Remove the 4 bolts and generator bracket sub-assembly from the cylinder head sub-assembly and timing chain case assembly.

  6. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A003I3K

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  7. REMOVE ENGINE OIL COOLER SET


    1. A003DPO

      Remove the 5 nuts and bolt from the engine oil cooler set.

      Text in Illustration
      A003DCD Bolt
      A003GWQ Nut

    2. Remove the engine oil cooler set and water outlet pipe gasket from the cylinder block sub-assembly.

    3. A003D63

      Remove the 2 O-rings from the cylinder block sub-assembly.

  8. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A003IBFE01

      Using SST, remove the oil filter sub-assembly.

      SST
      09228-07502

      Tech Tips


      • Before removing the oil filter sub-assembly, place cloth where the oil may splash.


      • Use a container to catch the draining engine oil.

  9. REMOVE OIL FILTER UNION


    1. A003AJK

      Using a 27 mm deep socket wrench, remove the oil filter union from the oil filter bracket.

  10. REMOVE OIL FILTER BRACKET


    1. A003E21

      Remove the bolt, 2 nuts and oil filter bracket from the cylinder block sub-assembly.

    2. Remove the 2 O-rings from the cylinder block sub-assembly.

  11. REMOVE INJECTOR ASSEMBLY


    1. A003D7Y

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

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

      When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

    3. Remove the O-ring from each injector assembly.

  12. REMOVE NOZZLE HOLDER GASKET


    1. A003BQS

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

  13. REMOVE CAMSHAFT POSITION SENSOR


    1. A003I4E

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  15. REMOVE OIL FILLER CAP GASKET


    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003CXE

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      A003DCD Bolt
      A003GWQ Nut
      A003G0E Nozzle Holder Clamp Seat
    2. A003BSPE01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  17. REMOVE NO. 5 CYLINDER BLOCK INSULATOR


    1. A003AD4

      Remove the No. 5 cylinder block insulator from the cylinder block sub-assembly.

  18. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A003I00

      Remove the No. 1 cylinder block insulator from the cylinder block sub-assembly.

  19. REMOVE CRANKSHAFT POSITION SENSOR HARNESS BRACKET


    1. A003I12

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor harness bracket from the cylinder block sub-assembly.

  20. REMOVE CRANKSHAFT POSITION SENSOR

    A003GG0

    1. Remove the bolt and crankshaft position sensor from the rear oil seal retainer.

  21. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the engine oil level sensor connector.

    2. A003BW9

      Remove the 4 bolts and engine oil level sensor from the oil pan sub-assembly.

  22. REMOVE OIL PAN SUB-ASSEMBLY


    1. A003FMY

      Remove the 2 nuts and 23 bolts.

      Text in Illustration
      A003DCD Bolt
      A003GWQ Nut
    2. A003HYZ

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

      • Be careful not to damage the cylinder block sub-assembly flange.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A003GAA

      Remove the 5 bolts, oil strainer sub-assembly and gasket from the cylinder block sub-assembly.

  24. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A003BPK

      Remove the 5 bolts.

    2. A003B0S

      Remove the rear engine oil seal retainer by prying between the rear engine oil seal retainer and cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE REAR ENGINE OIL SEAL


    1. A003H2WE01
      Text in Illustration
      *a Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

    2. Using a screwdriver, tap out the rear engine oil seal from the rear engine oil seal retainer.

      Note

      Do not damage the surface of the rear engine oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A003EDK

      Remove the 8 bolts, engine water pump assembly and gasket from the timing chain case assembly.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

    2. A003BQYE01
      Text in Illustration
      *a Timing Mark

      Align the timing mark of the crankshaft pulley and timing chain cover sub-assembly by rotating the crankshaft clockwise.

    3. 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).

  28. REMOVE TIMING CHAIN COVER PLATE

    A003F9X

    1. Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  29. REMOVE SUPPLY PUMP ASSEMBLY

    Note

    Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.

    A003C23

    1. A003AE6E01
      Text in Illustration
      *a Hold
      A003DCD Turn

      Using SST, hold the crankshaft pulley and loosen the supply pump shaft nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      Note

      Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.

      Tech Tips

      Rotate the supply pump shaft nut once to loosen it.

    2. A003CY9E01
      Text in Illustration
      *a Engine Front Side
      *b Engine Rear Side
      *c Hexagonal Portion

      Install SST to the timing chain cover sub-assembly with the 3 bolts.

      SST
      09241-11010
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips


      • Make sure that the installation direction of SST is as shown in the illustration.

      • A003FPBE01

        Align the hexagonal portion of SST with the supply pump shaft nut to install SST.

    3. A003FCG

      Remove the 2 bolts and No. 1 fuel pump bracket from the cylinder block sub-assembly and supply pump assembly.

    4. A003F80

      Loosen the 3 nuts to the ends of the stud bolts.

      Note

      Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.

    5. A003AQLE01

      Using SST, loosen the supply pump shaft nut and detach the supply pump assembly and injection pump drive gear.

    6. Remove the 3 nuts from the stud bolts.

    7. Remove the O-ring from the supply pump assembly.

    8. Remove SST from the timing chain cover sub-assembly.

    9. A003C1G

      Remove the supply pump shaft nut from the timing chain cover sub-assembly service hole.

    10. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

  30. REMOVE INJECTION PUMP INSULATOR


    1. A003BWU

      Remove the injection pump insulator from the cylinder block sub-assembly.

  31. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A003GF7

      Remove the 20 bolts from the timing chain cover sub-assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the points in the illustration.

      A003APKE01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain cover sub-assembly and timing chain case assembly.

    3. A003HCN

      Remove the timing chain case gasket from the timing chain case assembly.

  32. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A003HQAE01
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pull out the front crankshaft oil seal.

      Note

      Do not damage the surface of the front crankshaft oil seal press fit hole.

  33. REMOVE OIL PUMP RELIEF VALVE PLUG


    1. A003D8I

      Remove the oil pump relief valve plug and gasket from the timing chain cover sub-assembly.

  34. INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR


    1. A003GB0

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.3 mm (0.000787 to 0.0118 in.)
      Maximum gear backlash
      0.42 mm (0.0165 in.)

      If the gear backlash is more than the maximum, replace the timing chain case assembly or oil pump drive gear.

  35. REMOVE OIL PUMP DRIVE GEAR


    1. A003GX4

      Remove the oil pump drive gear from the crankshaft.

  36. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 3 chain tensioner assembly, the plunger and 2 springs may come off of the No. 3 chain tensioner assembly body, but this is not a malfunction.

    • A003DM0E01

      Before installing the plunger and 2 springs to the No. 3 chain tensioner assembly body, check that they are free of foreign matter and not damaged.


    1. A003CSJE01
      Text in Illustration
      *a No. 3 Chain Tensioner Assembly Body
      *b Spring
      *c Plunger

      Fully insert the plunger, align the No. 3 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

    2. A003GLP
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Remove the 2 bolts, No. 3 chain tensioner assembly and gasket from the engine balancer assembly.

  37. REMOVE NO. 1 BALANCE SHAFT THRUST PLATE


    1. A003EB7

      Remove the bolt and No. 1 balance shaft thrust plate from the balance shaft gear sub-assembly.

  38. REMOVE BALANCE SHAFT TIMING SPROCKET, BALANCE SHAFT GEAR SUB-ASSEMBLY WITH NO. 3 CHAIN SUB-ASSEMBLY


    1. A003HRI

      Remove the balance shaft timing sprocket, balance shaft gear sub-assembly with No. 3 chain sub-assembly from the crankshaft and engine balancer assembly.

  39. REMOVE ENGINE BALANCER ASSEMBLY


    1. A003GVB

      Remove the 8 bolts and engine balancer assembly from the cylinder block sub-assembly.

  40. REMOVE TIMING CHAIN GUIDE


    1. A003DY7

      Remove the bolt and timing chain guide from the cylinder head sub-assembly.

  41. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A003EUWE01
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate clockwise to release the lock. Once the lock is released, push the plunger into the No. 2 chain tensioner assembly.

    2. A003AHTE01
      Text in Illustration
      *a Pin

      Allow the plunger to extend slightly, and then rotate the stopper plate clockwise to release the lock. Once the lock is released, push the plunger into the No. 2 chain tensioner assembly.

    3. A003DLT

      Remove the 2 bolts and No. 2 chain tensioner assembly from the timing chain case assembly.

  42. REMOVE NO. 2 CHAIN TENSIONER SLIPPER


    1. A003CS5

      Remove the bolt and No. 2 chain tensioner slipper from the timing chain case assembly.

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A003HJM

      Remove the 2 bolts and No. 2 chain vibration damper from the timing chain case assembly.

  44. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. Remove the No. 2 chain sub-assembly from the camshaft timing sprockets and injection pump drive gear.

  45. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 1 chain tensioner assembly, the plunger and spring may come off of the No. 1 chain tensioner assembly body, but this is not a malfunction.

    • A003DH8E01

      Before installing the plunger and spring to the No. 1 chain tensioner assembly body, check that they are free of foreign matter and not damaged.

    Text in Illustration
    *a No. 1 Chain Tensioner Assembly Body
    *b Spring
    *c Plunger

    1. A003HZ4E01
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Fully insert the plunger, align the No. 1 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

    2. Remove the 2 bolts, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

  46. REMOVE NO. 1 CHAIN TENSIONER SLIPPER


    1. A003DBH

      Remove the No. 1 chain tensioner slipper from the straight pin.

  47. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A003AD8

      Remove the bolt and No. 1 chain vibration damper from the cylinder block sub-assembly.

  48. REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY


    1. A003FL4

      Remove the crankshaft timing sprocket, injection pump drive gear with No. 1 chain sub-assembly from the crankshaft and supply pump shaft.

  49. REMOVE CAMSHAFT TIMING SPROCKET


    1. for Exhaust Side:


      1. A003GEGE01
        Text in Illustration
        *a Hold
        A003DCD Turn

        Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the No. 2 camshaft.

        Note

        Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

    2. for Intake Side:


      1. A003DVCE01
        Text in Illustration
        *a Hold
        A003DCD Turn

        Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the camshaft.

        Note

        Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

  50. REMOVE TIMING CHAIN CASE ASSEMBLY


    1. A003EFT

      Remove the 15 bolts from the timing chain case assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain case assembly by prying the points in the illustration.

      A003H04E01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain case assembly, cylinder head sub-assembly and cylinder block sub-assembly.

    3. A003CZB

      Remove the 4 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.

    4. A003I3E

      Remove the No. 2 water pump gasket from the timing chain case assembly.

  51. REMOVE NO. 3 CAMSHAFT BEARING CAP


    1. A003AGH

      Remove the 2 camshaft bearing cap bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.

  52. REMOVE NO. 1 AND NO. 2 CAMSHAFT BEARING CAP


    1. A003CH3E01

      Remove the 20 camshaft bearing cap bolts in the sequence shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  53. REMOVE CAMSHAFT


    1. Remove the camshaft from the cylinder head sub-assembly.

  54. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the cylinder head sub-assembly.

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


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the 16 valve lash adjuster assemblies.

  56. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

  57. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003H8ME01

      Uniformly loosen the 10 cylinder head set bolts in several passes in the sequence shown in the illustration. Then remove the 10 cylinder head set bolts and 6 cylinder head set bolt spacers.

      Note


      • Cylinder head sub-assembly warpage or cracking could result from removing bolts in the incorrect order.

      • Be careful not to drop the cylinder head set bolt spacers into the cylinder head sub-assembly.

    2. Lift the cylinder head sub-assembly from the ring pins on the cylinder block sub-assembly, and place the cylinder head sub-assembly on wooden blocks on a bench.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

      Tech Tips

      If the cylinder head sub-assembly is difficult to remove, use a screwdriver to pry between the cylinder head sub-assembly and cylinder block sub-assembly.

  58. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block sub-assembly.

  59. REMOVE LOCK PLATE


    1. A003BWE

      Remove the bolt and lock plate from the cylinder block sub-assembly.

  60. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

  61. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pin unless it is being replaced.