ENGINE UNIT(w/ Glow Plug Controller) DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  2. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B0041T2

      Remove the 3 bolts, 2 nuts and water outlet sub-assembly from the cylinder head sub-assembly.

    2. B0044IT

      Remove the water outlet gasket from the cylinder head sub-assembly.

  3. REMOVE WATER INLET


    1. B0043X1

      Remove the 3 bolts and water inlet from the water inlet housing.

    2. B0042DH

      Remove the No. 1 water inlet housing gasket from the water inlet.

  4. REMOVE OIL PRESSURE SENDER GAGE ASSEMBLY

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  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B0044IM

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

    2. B0044Y9

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

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0042QO

      Remove the 11 bolts, nut and cylinder head cover sub-assembly from the cylinder head sub-assembly.

    2. B0042JQ

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  7. REMOVE ENGINE MOUNTING BRACKET RH


    1. B0043RO

      Remove the 4 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.

  8. REMOVE NO. 2 TIMING CHAIN COVER


    1. B0042QN

      Remove the bolt and manifold temperature sensor bracket from the timing chain cover sub-assembly.

    2. Remove the No. 2 timing chain cover from the timing chain cover sub-assembly.

  9. REMOVE CAMSHAFT POSITION SENSOR


    1. B0042YZ

      Remove the bolt and camshaft position sensor from the timing chain cover sub-assembly.

      Note

      If a component has been dropped or subjected to a strong impact, replace the camshaft position sensor.

  10. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  11. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B00450A

      Remove the bolt and oil pressure switching valve assembly from the timing chain cover sub-assembly.

      Note

      If a component has been dropped or subjected to a strong impact, replace the oil pressure switching valve assembly.

    2. B0044ZL

      Remove the 20 bolts and 2 nuts.

    3. B0041ZTC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover sub-assembly by prying between the cylinder head sub-assembly and cylinder block sub-assembly.

      Note

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

    4. B00449U

      Remove the oil pump gasket from the oil pan sub-assembly.

  12. REMOVE TIMING CHAIN COVER OIL SEAL


    1. B0042K7C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover oil seal from the timing chain cover sub-assembly.

  13. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. B00427Q

      Using a 5 mm hexagon wrench, remove the bolt and oil check valve sub-assembly from the timing chain cover sub-assembly.

  14. REMOVE WATER INLET HOUSING


    1. B0043A6

      Remove the 3 bolts and water inlet housing from the timing chain cover sub-assembly.

    2. B0043WC

      Remove the No. 2 water inlet housing gasket from the inlet water housing.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.


    1. B0041QRC01
      *a Plunger
      *b Groove
      *c Hole
      B0042CO Push

      Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.0433 in.) diameter bar.

    2. B0043LG

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

  16. REMOVE CHAIN TENSIONER SLIPPER


    1. B0043P5

      Remove the chain tensioner slipper from the cylinder head sub-assembly.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B0044FV

      Using an 8 mm socket hexagon wrench, remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.

  18. REMOVE CHAIN SUB-ASSEMBLY


    1. B0042SNN01

      Using SST, hold the camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 3 bolts and sensor plate.

    3. B0042OV

      Remove the camshaft timing sprocket, crankshaft timing sprocket and chain sub-assembly together.

  19. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. B0043N9

      Remove the chain tensioner plate with the chain damper spring from the pin.

    2. B0042TN

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

    3. B0043W2

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly together.

  20. REMOVE CHAIN DAMPER SPRING


    1. B0043TI

      Remove the chain damper spring from the chain tensioner plate.

  21. REMOVE CAMSHAFT

    Click here

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


    1. B0041N9

      Remove the 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

  23. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B00427LN01

      Loosen and remove the 10 cylinder head set bolts and 10 cylinder head set plate washers in several steps in the order shown in the illustration.

      Note


      • When removing the cylinder head set bolts, do not drop the plate washers into the engine.

      • Removing the cylinder head set bolts in the wrong order may cause damage to the cylinder head sub-assembly.

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

  24. REMOVE CYLINDER HEAD GASKET

    Click here

  25. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B00451T

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

  26. REMOVE OIL FILTER ELEMENT

    Click here

  27. REMOVE OIL COOLER ASSEMBLY


    1. B0042KWC01
      *a Nut and Plate Washer

      Remove the 2 bolts, 2 nuts, 2 plate washers and oil cooler assembly from the oil filter bracket sub-assembly.

    2. B0041YM

      Remove the 2 O-rings and gasket from the oil filter bracket sub-assembly.

  28. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. B0042SR

      Remove the 2 bolts and oil filter bracket sub-assembly from the oil pan sub-assembly.

    2. B0041SL

      Remove the oil filter bracket gasket from the oil pan sub-assembly.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B00438H

      Remove the oil pan drain plug and oil pan drain plug gasket from the No. 2 oil pan sub-assembly.

    2. Remove the 10 bolts and 2 nuts.

    3. B0042YMC01
      *a Oil Pan Seal Cutter

      Insert the oil pan seal cutter blade between the oil pan sub-assembly and No. 2 oil pan sub-assembly, and cut off the applied sealer.

      Note

      Do not damage the oil pan sub-assembly or No. 2 oil pan sub-assembly.

    4. Remove the No. 2 oil pan sub-assembly from the oil pan sub-assembly.

  30. REMOVE ENGINE OIL LEVEL SENSOR


    1. B0044UF

      Remove the 5 bolts and engine oil level sensor from the oil pan sub-assembly.

  31. REMOVE OIL PAN SUB-ASSEMBLY


    1. B0042FP

      Remove the 12 bolts.

    2. B00433SC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the oil pan sub-assembly by prying between the cylinder block sub-assembly and oil pan sub-assembly.

      Note


      • Do not apply excessive force when prying between the cylinder block sub-assembly and oil pan sub-assembly.

      • Do not damage the contact surface of the cylinder block sub-assembly and oil pan sub-assembly.

  32. REMOVE ENGINE REAR OIL SEAL


    1. B0044WV

      Remove the engine rear oil seal from the crankshaft and cylinder block sub-assembly.