ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE NOZZLE HOLDER SEAL

    Click here

  3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  4. REMOVE INJECTOR ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT TIMING PULLEY

    Click here

  6. REMOVE NO. 2 TIMING BELT COVER

    Click here

  7. REMOVE CYLINDER BLOCK INSULATOR

    Click here

  8. REMOVE CAMSHAFT

    Click here

  9. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  10. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  11. REMOVE CYLINDER HEAD GASKET

  12. REMOVE WATER PUMP ASSEMBLY


    1. B001DBB

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

  13. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump.


    1. B001EH9

      Remove the 14 bolts and 2 nuts.

    2. A01XGPW

      Pry the gear cover at the locations shown in the illustration, and remove the gear cover together with the injection gear.

      Note

      Be careful not to drop the injection gear.

    3. A01XGUW

      Remove the O-ring from the timing gear case.

  14. REMOVE INJECTION GEAR


    1. A01XG08

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.

    2. A01XM7V

      Remove the injection gear.

  15. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01XGZ6

      Remove the No. 1 crankshaft position sensor plate.

  16. REMOVE CRANKSHAFT TIMING GEAR


    1. A01XMROE01

      Using SST, remove the crankshaft timing gear.

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

  17. REMOVE IDLE GEAR THRUST PLATE


    1. A01XGZM

      Remove the 2 bolts and thrust plate.

  18. REMOVE NO. 1 IDLE GEAR


    1. A01XEHM

      Remove the No. 1 idle gear together with No. 2 idle sub gear.

  19. REMOVE NO. 1 IDLE SUB GEAR


    1. A01XIUN

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

      Note

      Be careful not to damage the gears.

    2. A01XGHIE02
      Text in Illustration
      *1 Service Bolt

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

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
    3. B001HJT

      Using snap ring pliers, remove the shaft snap ring.

    4. A01XHR4E04
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 1 idle sub gear and idle gear spring.

  20. REMOVE NO. 2 IDLE SUB GEAR


    1. A01XMB4

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

      Note

      Be careful not a damage the gear.

    2. B001FEF

      Using snap ring pliers, remove the shaft snap ring.

    3. A01XGANE05
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 2 idle sub gear and idle gear spring.

  21. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01XJ6R

      Remove the idle gear shaft.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01XC8J

      Remove the 11 bolts and 2 nuts.

    2. A01XF4P

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01XGJY

      Remove the 2 nuts, oil strainer and gasket.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01XHK3

      Remove the 22 bolts and 2 nuts.

    2. A01XMRLE01
      Text in Illustration
      *A LH Side
      *B RH Side
      *1 Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

    3. A01XHW1

      Remove the gasket.

  25. REMOVE TIMING GEAR CASE ASSEMBLY


    1. B001HBW

      Remove the union bolt and 8 bolts.

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

    3. Remove the 2 O-rings.

  26. INSPECT NO. 1 BALANCESHAFT THRUST CLEARANCE


    1. A01XCUY

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balanceshaft back and forth.

      Standard thrust clearance
      0.065 to 0.140 mm (0.00256 to 0.00551 in.)
      Maximum thrust clearance
      0.25 mm (0.00984 in.)

      If the thrust clearance is more than the maximum clearance, replace the balanceshaft thrust washer.

      If the thrust clearance would still be more than the maximum clearance, replace the No. 1 baranceshaft sub-assembly.

  27. REMOVE NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. B001G7D

      Remove the 2 bolts and balanceshaft.

  28. REMOVE NO. 1 BALANCESHAFT DRIVEN GEAR


    1. B001EVS

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

    2. Remove the bolt, balanceshaft driven gear and balanceshaft thrust washer.

  29. INSPECT NO. 2 BALANCESHAFT THRUST CLEARANCE


    1. A01XCUY

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balanceshaft back and forth.

      Standard thrust clearance
      0.065 to 0.140 mm (0.00256 to 0.00551 in.)
      Maximum thrust clearance
      0.25 mm (0.00984 in.)

      If the thrust clearance is more than the maximum clearance, replace the balanceshaft thrust washer.

      If the thrust clearance would still be more than the maximum clearance, replace the No. 2 baranceshaft sub-assembly.

  30. REMOVE NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. B001CH2

      Remove the 2 bolts and balanceshaft.

  31. REMOVE NO. 2 BALANCESHAFT DRIVEN GEAR


    1. B001DFW

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

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

  32. REMOVE REAR ENGINE OIL SEAL RETAINER

    A01XFJB

    1. Remove the 5 bolts.

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

  33. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01XK94

      Using a screwdriver and hammer, tap out the oil seal.

  34. REMOVE SUPPLY PUMP OIL SEAL


    1. A01XCFE

      Using a screwdriver and hammer, tap out the oil seal.

  35. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01XDVE

      Using a screwdriver and hammer, tap out the oil seal.