БЛОК ДВИГАТЕЛЯ РАЗБОРКА

PROCEDURE


  1. PRECAUTION

    Note


    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A01M29ZE02

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST
      PZ4TB-04941-79

  2. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  3. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  6. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  7. REMOVE INJECTOR ASSEMBLY

    Click here

  8. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  9. REMOVE WATER BY-PASS PIPE

    A01M0X7

    1. Using a 5 mm hexagon socket wrench, remove the bolt and water by-pass pipe from the water inlet housing.

  10. REMOVE WATER INLET

    Click here

  11. REMOVE THERMOSTAT

    Click here

  12. REMOVE WATER INLET HOUSING


    1. A01LWC7

      Using an E11 "TORX" socket wrench, remove the 5 bolts and water inlet housing.

  13. REMOVE WATER OUTLET


    1. A01M21L

      Using an E10 "TORX" socket wrench, remove the 3 bolts and water outlet.

    2. Remove the gasket from the water outlet.

  14. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  15. REMOVE OIL FILTER ASSEMBLY

    Click here

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  17. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  19. SECURE CAMSHAFT AND NO. 2 CAMSHAFT

    Click here

  20. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  21. REMOVE NO. 2 TIMING CHAIN GUIDE

    Click here

  22. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

    Click here

  23. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

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

    Click here

  25. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  26. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  27. REMOVE CYLINDER HEAD GASKET

    Click here

  28. REMOVE CRANKSHAFT PULLEY

    Click here

  29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  30. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  31. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  32. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY

    Click here

  33. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01M1L2

      Remove the sealing cap from the timing chain cover plate.

    2. Remove the O-ring from the sealing cap.

    3. A01LWG6N02

      Using SST (B), install SST (A) to position the fuel supply pump assembly. Then remove SST (B).

      SST
      PZ4TB-04967-25

      Note

      Do not remove SST (A) from the timing chain cover plate until all repair work has been completed.

    4. A01M3D6

      Remove the 4 bolts and fuel supply pump assembly support.

    5. A01M1H1

      Remove the 2 bolts from the fuel supply pump assembly.

    6. A01LZP0E01
      A01LVPYC01
      *1 Central Bolt

      Loosen the central bolt connection between the fuel supply pump assembly and injection pump drive gear.

      Note


      • Do not remove SST (A) from the timing chain cover plate.

      • The central bolt is supported on SST (A) until the fuel supply pump assembly is pressed out.

      • Do not remove the central bolt from SST (A) until all repair work has been completed.

    7. Remove the fuel supply pump assembly from the cylinder block.

  34. REMOVE OIL PAN SUB-ASSEMBLY

    Click here

  35. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  36. REMOVE OIL PUMP WITH VACUUM PUMP ASSEMBLY

    Click here

  37. REMOVE REAR ENGINE OIL SEAL

    Click here

  38. REMOVE TIMING CHAIN COVER PLATE


    1. A01LY5N

      Using an E8 "TORX" socket wrench, remove the 11 bolts and timing chain cover plate.

  39. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. A01LV65

      Remove the oil pump drive chain sub-assembly from the crankshaft.

  40. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01LW5P

      Remove the No. 2 chain sub-assembly from the injection pump drive gear.

  41. REMOVE NO. 2 TIMING CHAIN TENSION ARM


    1. A01M218

      Using a T45 "TORX" socket wrench, remove the bolt and No. 2 timing chain tension arm.

  42. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01M21AC01
      *a Hexagon Wrench

      Slowly push the plunger deep into the No. 1 chain tensioner assembly and insert a 3.0 mm hexagon wrench into the No. 1 chain tensioner assembly.

    2. A01LXPJ

      Using an E8 "TORX" socket wrench, remove the 2 bolts and No. 1 chain tensioner assembly.

  43. REMOVE TIMING CHAIN TENSION ARM


    1. A01LWL8

      Using a T45 "TORX" socket wrench, remove the bolt and timing chain tension arm.

  44. REMOVE TIMING CHAIN GUIDE


    1. A01LZW4

      Using a T45 "TORX" socket wrench, remove the 2 bolts and timing chain guide.

  45. REMOVE INJECTION PUMP DRIVE GEAR


    1. A01M1DL

      Remove the injection pump drive gear and chain sub-assembly.

  46. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01M01L

      Using an E8 "TORX" socket wrench, remove the bolt and No. 2 oil nozzle sub-assembly.