ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  3. REMOVE INJECTOR ASSEMBLY

    Click here

  4. REMOVE CAMSHAFT TIMING PULLEY

    Click here

  5. REMOVE NO. 2 TIMING BELT COVER

    Click here

  6. REMOVE CYLINDER BLOCK INSULATOR


    1. Remove the cylinder block insulator from the cylinder head sub-assembly.

  7. REMOVE CAMSHAFT SUB-ASSEMBLY

    Click here

  8. REMOVE VALVE LIFTER


    1. Remove the valve lifters from the cylinder head sub-assembly.

      Tech Tips

      Arrange the valve lifters in the correct order.

  9. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  10. REMOVE CYLINDER HEAD GASKET

  11. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B00260J

      Remove the 5 bolts, 2 nuts, engine water pump assembly and gasket from the cylinder block sub-assembly.

  12. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump assembly is not installed, the injection gear is loose inside the timing gear case assembly. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump assembly.


    1. Remove the bolt and No. 1 vacuum transmitting pipe.

    2. B0024PO

      Remove the 14 bolts and 2 nuts.

    3. B0025ND

      Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

      Note

      Be careful not to drop the injection gear.

    4. B0025UU

      Remove the O-ring from the timing gear case assembly.

  13. REMOVE INJECTION GEAR


    1. B002784

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.

    2. B0026K6

      Remove the injection gear from the timing gear case assembly.

  14. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B0025KF

      Remove the No. 1 crankshaft position sensor plate from the crankshaft.

  15. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO OIL PUMP GEAR


    1. B0025EI

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.000787 to 0.00591 in.)
      Maximum gear backlash
      0.2 mm (0.00787 in.)

      If the gear backlash is more than the maximum, replace the crankshaft timing gear or timing gear case assembly.

  16. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO NO. 1 IDLE GEAR


    1. B0027AI

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.000787 to 0.00591 in.)
      Maximum gear backlash
      0.2 mm (0.00787 in.)

      If the gear backlash is more than the maximum, replace the crankshaft timing gear or No. 1 idle gear.

  17. INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE


    1. B0028VA

      Using a dial indicator, measure the thrust clearance.

      Standard thrust clearance
      0.06 to 0.11 mm (0.00236 to 0.00433 in.)
      Maximum thrust clearance
      0.3 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the idle gear thrust plate. If necessary, replace the No. 1 idle gear or No. 1 idle gear shaft.

  18. REMOVE CRANKSHAFT TIMING GEAR


    1. B00278ON03

      Using SST, remove the crankshaft timing gear from the crankshaft.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  19. INSPECT BACKLASH OF INJECTION GEAR TO NO. 1 IDLE GEAR


    1. Install the fuel supply pump assembly with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. B0027YKN03

      Using SST, install the injection gear with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }
    3. B0024K4

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.000787 to 0.00591 in.)
      Maximum gear backlash
      0.2 mm (0.00787 in.)

      If the gear backlash is more than the maximum, replace the injection gear or No. 1 idle gear.

    4. B0027YKN03

      Using SST, remove the nut and injection gear.

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

    5. Remove the 2 nuts and fuel supply pump assembly.

  20. REMOVE IDLE GEAR THRUST PLATE


    1. B0026MS

      Remove the 2 bolts and idle gear thrust plate from the No. 1 idle gear shaft.

  21. REMOVE NO. 1 IDLE GEAR


    1. B0027ME

      Remove the No. 1 idle gear together with the No. 2 idle sub gear from the No. 1 idle gear shaft.

  22. REMOVE NO. 2 IDLE SUB GEAR


    1. B0024I0C05
      *1 Service Bolt
      *2 No. 1 Idle Gear
      *3 No. 2 Idle Sub Gear
      B0068HS Turn

      Using SST, turn the No. 2 idle sub gear clockwise and remove the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    2. B0025MW

      Using snap ring pliers, remove the snap ring.

    3. Remove the wave washer, No. 2 idle sub gear and gear spring.

  23. REMOVE NO. 1 IDLE GEAR SHAFT


    1. B0025EU

      Remove the No. 1 idle gear shaft from the timing gear case assembly.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 22 bolts and 2 nuts.

    2. B0027M1

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly, cut through the applied sealer and remove the oil pan sub-assembly from the cylinder block sub-assembly.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan sub-assembly and timing gear case assembly, or for the area between the oil pan sub-assembly and rear oil seal retainer.

      • Be careful not to damage the oil pan sub-assembly flange.

  25. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the 2 bolts, 2 nuts, oil strainer sub-assembly and gasket from the cylinder block sub-assembly.

  26. REMOVE TIMING GEAR CASE ASSEMBLY


    1. Remove the bolt and No. 1 vacuum transmitting pipe.

    2. B0028XS

      Remove the union bolt and 8 bolts.

    3. Pry the timing gear case assembly at the location shown in the illustration and remove the timing gear case assembly and gasket from the cylinder block sub-assembly.

    4. B0025DB

      Remove the 2 O-rings from the cylinder block sub-assembly.

  27. REMOVE REAR ENGINE OIL SEAL RETAINER

    B00286R

    1. Remove the 5 bolts.

    2. Using a screwdriver, remove the rear engine oil seal retainer by prying between the rear engine oil seal retainer and cylinder block sub-assembly.

  28. REMOVE REAR ENGINE OIL SEAL


    1. B0026NT

      Using a screwdriver and hammer, tap out the rear engine oil seal from the rear engine oil seal retainer.

  29. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B002719

      Using a screwdriver and hammer, tap out the front crankshaft oil seal from the timing gear cover.

  30. REMOVE INJECTION PUMP OIL SEAL


    1. B0025JJ

      Using a screwdriver and hammer, tap out the injection pump oil seal from the timing gear cover.