ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When replacing the injector assemblies (including exchanging the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.

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

PROCEDURE


  1. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A012HDSC04
      *1 No. 2 Nozzle Leakage Pipe
      *a 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. A012LVY

      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. A012GCJ

      Remove the 4 bolts, 4 washers and 4 No. 1 nozzle holder clamps.

  4. REMOVE INJECTOR ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A012JGW

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A012FEU

      Remove the clip and disconnect the crankshaft position sensor harness.

    2. Remove the 2 bolts and crankshaft position sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A012IG0N01

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  8. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  9. REMOVE OIL PRESSURE SENDER GAUGE 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. A012LRE

      Remove the 4 bolts and engine oil level sensor.

  13. REMOVE WATER INLET HOUSING

    Click here

  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  15. REMOVE OIL PAN SUB-ASSEMBLY

    Click here

  16. REMOVE OIL FILTER ELEMENT

    Click here

  17. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

    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 cylinder to TDC/compression.


      1. A012GGMC04
        *a Timing Pointer
        *b Timing Mark

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

    2. A012LOUC02
      *a Matchmark
      *b 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 cylinder 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 pink-colored mark plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A012GSSN01

      Turn the crankshaft pulley approximately 90° clockwise from the timing pointer on the timing chain cover sub-assembly so that a lifted valve and piston will not contact each other when removing the camshafts.

    5. A012KWJN01

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A012I7YN01

      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. A012K4BC04
      *a Plunger
      *b Stopper Plate

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

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

      SST
      09240-00020   ( 09242-00200 )
    3. A012LUI

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

  24. REMOVE CHAIN TENSIONER SLIPPER

    A012I27

    1. Remove the chain tensioner slipper from the cylinder block sub-assembly.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A012M5G

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

  26. REMOVE CAMSHAFT TIMING SPROCKET


    1. A012GG4

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

    2. Remove the camshaft timing sprocket and chain sub-assembly.

  27. REMOVE OIL PUMP DRIVE GEAR


    1. A012HAX

      Remove the oil pump drive gear from the crankshaft.

  28. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A012NCT

      Remove the crankshaft timing sprocket from the crankshaft.

  29. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. A012GOE

      Remove the 2 crankshaft pulley set crankshaft 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

    Click here

  35. REMOVE REAR CRANKSHAFT OIL SEAL

    Click here

  36. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A012HT3

      Remove the 4 bolts and No. 1 oil pan baffle plate.

  37. REMOVE CYLINDER BLOCK DRAIN COCK PLUG


    1. A012I9V

      Remove the cylinder block drain cock plug from the cylinder block sub-assembly.