ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 ENGINE HANGER


    1. B003R9W

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

  2. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. B003LKC

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

  3. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B003QGJ

      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. B003LJO

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

  5. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. B003L75

      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. B003O3W

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

  7. REMOVE ENGINE OIL COOLER SET

    Click here

  8. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  9. REMOVE OIL FILTER UNION


    1. B003ORU

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

  10. REMOVE OIL FILTER BRACKET


    1. B003MPJ

      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. B003PLE

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

  18. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. B003OER

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

  19. REMOVE CRANKSHAFT POSITION SENSOR HARNESS BRACKET


    1. B003N1V

      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 OIL PAN COVER SILENCER

    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. B003OQE

      Remove the 4 bolts, oil strainer sub-assembly and gasket from the cylinder block sub-assembly.

  25. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B003JH0

      Remove the 5 bolts.

    2. B003RBY

      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. B003MAEC01
      *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. B003POYC01
      *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.

    B003NIOC07
    *A w/ DPF
    *B w/o DPF

    1. B003NZSC01
      *a Hold
      B003R2S 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. B003QDPN01

      Install SST with the 3 bolts to the timing chain cover sub-assembly.

      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.

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

      B003P6PC02
      *a Engine Front Side
      *b Engine Rear Side
      *c Hexagonal Portion
    3. B003KLF

      w/ DPF:

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

    4. B003KW9C03
      *A w/ DPF
      *B w/o DPF

      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. B003QEAN01

      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. B003OZB

      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. B003L3L

      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. B003NY3

      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 TIMING CHAIN GUIDE

    Click here

  38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003KNAC01
      *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. B003Q93C01
      *a Pin

      Move the stopper plate counterclockwise to set the lock, and then insert a pin into the stopper plate hole.

    3. B003P0S

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

  39. REMOVE NO. 2 CHAIN TENSIONER SLIPPER


    1. B003LVK

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

  40. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B003NNQ

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

  41. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


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

  42. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    B003LYUC01
    *a No. 1 Chain Tensioner Assembly Body
    *b Spring
    *c Plunger

    • 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.

    • 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.


    1. B003RZFC01
      *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. B003M1G

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

  43. REMOVE NO. 1 CHAIN TENSIONER SLIPPER


    1. B003QYL

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

  44. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B003LWC

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

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


    1. B003PBH

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

  46. REMOVE CAMSHAFT TIMING SPROCKET


    1. for Exhaust Side:


      1. B003M7NC01
        *a Hold
        B003R2S Turn

        Hold 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. B003KADC01
        *a Hold
        B003R2S Turn

        Hold 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.

  47. REMOVE TIMING CHAIN CASE ASSEMBLY

    Click here

  48. REMOVE NO. 3 CAMSHAFT BEARING CAP


    1. B003KDW

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

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


    1. B003LVIN01

      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.

  50. REMOVE CAMSHAFT


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

  51. REMOVE NO. 2 CAMSHAFT


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

  52. 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.

  53. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  55. REMOVE CYLINDER HEAD GASKET

    Click here

  56. REMOVE LOCK PLATE


    1. B003N1I

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

  57. REMOVE STUD BOLT

    Note

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

  58. REMOVE STRAIGHT PIN

    Note

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