ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 ENGINE HANGER


    1. B001HB6

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

  2. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. B001EO9

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

  3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B001IGI

      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. B001G37

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

  5. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. B001ILY

      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. B001CRQ

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

  7. REMOVE OIL COOLER ASSEMBLY

    Click here

  8. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  9. REMOVE OIL FILTER UNION


    1. B001I7T

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

  10. REMOVE OIL FILTER BRACKET


    1. B001HTA

      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

    Click here

  12. REMOVE NOZZLE HOLDER GASKET

    Click here

  13. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  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

    Click here

  17. REMOVE NO. 5 CYLINDER BLOCK INSULATOR


    1. B001DEH

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

  18. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. B001ER4

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

  19. REMOVE CRANKSHAFT POSITION SENSOR HARNESS BRACKET


    1. B001FI2

      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

    Click here

  21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  22. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  23. REMOVE OIL PAN SUB-ASSEMBLY

    Click here

  24. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B001ER5

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

  25. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B001D7C

      Remove the 5 bolts.

    2. B001CIH

      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.

  26. REMOVE REAR ENGINE OIL SEAL


    1. B001E2SE01
      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.

  27. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


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

    2. B001I1ZE01
      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).

  29. REMOVE TIMING CHAIN COVER PLATE

    Click here

  30. REMOVE SUPPLY PUMP ASSEMBLY

    Note

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

    B001DFG

    1. B001DQ6E01
      Text in Illustration
      *a Hold
      B001CHY 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. B001E7EE01
      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.

      • B001HLAE01

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

    3. B001CMF

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

    4. B001E55

      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. B001HI3E01

      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. B001EUJ

      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.

  31. REMOVE INJECTION PUMP INSULATOR


    1. B001E23

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

  32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  33. REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  34. REMOVE OIL PUMP RELIEF VALVE PLUG


    1. B001ECT

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

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

    Click here

  36. REMOVE OIL PUMP DRIVE GEAR

    Click here

  37. 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.

    • B001I2CE01

      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. B001G8DE01
      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. B001FYD
      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.

  38. REMOVE NO. 1 BALANCE SHAFT THRUST PLATE


    1. B001CJW

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

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


    1. B001EDC

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

  40. REMOVE ENGINE BALANCER ASSEMBLY


    1. B001F8Q

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

  41. REMOVE TIMING CHAIN GUIDE

    Click here

  42. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B001G29E01
      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. B001E9OE01
      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. B001FZ6

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

  43. REMOVE NO. 2 CHAIN TENSIONER SLIPPER


    1. B001I6C

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

  44. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B001HTR

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

  45. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


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

  46. 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.

    • B001E0RE01

      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. B001HXAE01
      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.

  47. REMOVE NO. 1 CHAIN TENSIONER SLIPPER


    1. B001FIA

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

  48. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B001F1U

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

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


    1. B001FUL

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

  50. REMOVE CAMSHAFT TIMING SPROCKET


    1. for Exhaust Side:


      1. B001DZOE01
        Text in Illustration
        *a Hold
        B001CHY 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. B001EYTE01
        Text in Illustration
        *a Hold
        B001CHY 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.

  51. REMOVE TIMING CHAIN CASE ASSEMBLY

    Click here

  52. REMOVE NO. 3 CAMSHAFT BEARING CAP


    1. B001HTS

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

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


    1. B001G57E01

      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.

  54. REMOVE CAMSHAFT


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

  55. REMOVE NO. 2 CAMSHAFT


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

  56. 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.

  57. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

  58. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  59. REMOVE CYLINDER HEAD GASKET

    Click here

  60. REMOVE LOCK PLATE


    1. B001FEE

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

  61. REMOVE STUD BOLT

    Note

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

  62. REMOVE STRAIGHT PIN

    Note

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