ENGINE UNIT (w/ DPF) DISASSEMBLY

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A00XD84E01

      Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. A00XH2E

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    3. A00XCKH

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  3. REMOVE INJECTOR ASSEMBLY


    1. A00XFVDE04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A00XDIKE02

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

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  4. REMOVE CAMSHAFT TIMING PULLEY


    1. A00O9HVE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  5. REMOVE NO. 2 TIMING BELT COVER


    1. A00O7OS

      Remove the 4 bolts, nut and No. 2 timing belt cover.

  6. REMOVE CYLINDER BLOCK INSULATOR


    1. A00O3A5

      Remove the cylinder block insulator from the cylinder head.

  7. REMOVE CAMSHAFT


    1. A00O46RE03
      Text in Illustration
      *1 Key Groove

      Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

    2. A00O5CUE01

      Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

    3. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.

  8. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  9. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00O5LDE01

      Uniformly loosen the 18 cylinder head bolts in several passes in the sequence shown in the illustration. Then remove the 18 cylinder head bolts and 18 washers.

      Note

      Head warpage or cracking could result from removing bolts in the incorrect order.

    2. Remove the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a workbench.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

      Tech Tips

      If the cylinder head is difficult to remove, use a screwdriver to pry between the cylinder head and block.

  10. REMOVE CYLINDER HEAD GASKET

  11. REMOVE WATER PUMP ASSEMBLY


    1. A00JUIH

      Remove the 5 bolts, 2 nuts, water pump and gasket.

  12. REMOVE TIMING GEAR COVER

    Note

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

    Tech Tips

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


    1. A00JXJS

      Remove the 14 bolts and 2 nuts.

    2. A00JWMV

      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.

    3. A00JZ5L

      Remove the 3 O-rings from the timing gear case.

  13. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. A00JU6Q

      Using a 6 mm hexagon wrench, remove the bolt and oil check valve from the timing gear cover.

  14. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A00JXBKE01
      Text in Illustration
      *1 Ball

      Push the ball of the oil check valve to check if it is stuck.

      If the check valve is stuck, replace the oil check valve sub-assembly.

  15. REMOVE INJECTION GEAR


    1. A00JZS1

      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. A00JVGT

      Remove the injection gear.

  16. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00JY21

      Remove the No. 1 crankshaft position sensor plate.

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


    1. A00K126E01

      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.

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


    1. A00JX3DE01

      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.

  19. INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE


    1. Install the timing gear case, No. 1 idle gear and camshaft timing gear.

    2. A00K1ROE01

      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.

  20. REMOVE CRANKSHAFT TIMING GEAR


    1. A00JXF2E01

      Using SST, remove the crankshaft timing gear.

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

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


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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A00K1F2E01

      Using SST, install the injection gear with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }
    3. A00JX1HE01

      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.

  22. REMOVE IDLE GEAR THRUST PLATE


    1. A00JUAU

      Remove the 2 bolts and idle gear thrust plate.

  23. REMOVE NO. 1 IDLE GEAR


    1. A00JZ8S

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

  24. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A00K1O0

      Remove the No. 1 idle gear shaft.

  25. INSPECT BACKLASH OF NO. 1 BALANCESHAFT TO OIL PUMP GEAR


    1. A00K1E2E01

      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 No. 1 balanceshaft sub-assembly or timing gear case assembly.

  26. INSPECT BACKLASH OF NO. 2 BALANCESHAFT TO INJECTION GEAR


    1. A00JX8VE01

      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 No. 2 balanceshaft assembly or injection gear.

    2. A00K1F2E01

      Using SST, remove the nut and injection gear.

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

    3. Remove the 2 nuts and fuel supply pump.

    4. Remove the gears and timing gear case.

  27. REMOVE NO. 1 IDLE SUB GEAR


    1. A00JUT0E01

      Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    2. A00K298E02
      Text in Illustration
      *1 Service Bolt

      Using SST, turn the No. 1 idle sub gear clockwise and remove the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
    3. A00K0Z9E01

      Using snap ring pliers, remove the shaft snap ring.

    4. A00K0AGE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 1 idle sub gear and idle gear spring.

  28. REMOVE NO. 2 IDLE SUB GEAR


    1. A00K1YTE01

      Turn the No. 1 idle gear over and set it in a vise.

      Note

      Be careful not a damage the gear.

    2. A00JVJLE01

      Using snap ring pliers, remove the shaft snap ring.

    3. A00JYZPE05
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

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

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00JVEN

      Remove the 11 bolts and 2 nuts.

    2. A00K0U4

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

  30. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00K0EM

      Remove the 2 nuts, oil strainer and gasket.

  31. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00JW3T

      Remove the 22 bolts and 2 nuts.

    2. A00JZWIE02
      Text in Illustration
      *A LH Side
      *B RH Side
      *a Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A00JXGA

      Remove the gasket.

  32. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A00JVR6

      Remove the union bolt and 8 bolts.

    2. A00JZII

      Pry the timing gear case at the location shown in the illustration and remove the gear case and gasket.

    3. A00K1GQE03

      Remove the 2 O-rings.

  33. INSPECT NO. 1 BALANCESHAFT THRUST CLEARANCE


    1. A00JUCEE01

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balanceshaft back and forth.

      Standard thrust clearance
      0.065 to 0.140 mm (0.00256 to 0.00551 in.)
      Maximum thrust clearance
      0.25 mm (0.00984 in.)

      If the thrust clearance is more than the maximum clearance, replace the balanceshaft thrust washer.

      If the thrust clearance is still more than the maximum clearance, replace the No. 1 balanceshaft sub-assembly.

  34. REMOVE NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. A00K0NEE01

      Remove the 2 bolts and balanceshaft.

  35. REMOVE NO. 1 BALANCESHAFT DRIVEN GEAR


    1. A00JYQJE01

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

    2. Remove the bolt, balanceshaft driven gear and balanceshaft thrust washer.

  36. INSPECT NO. 2 BALANCESHAFT THRUST CLEARANCE


    1. A00JUCEE01

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balanceshaft back and forth.

      Standard thrust clearance
      0.065 to 0.140 mm (0.00256 to 0.00551 in.)
      Maximum thrust clearance
      0.25 mm (0.00984 in.)

      If the thrust clearance is more than the maximum clearance, replace the balanceshaft thrust washer.

      If the thrust clearance is still more than the maximum clearance, replace the No. 2 balanceshaft sub-assembly.

  37. REMOVE NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. A00JV69E01

      Remove the 2 bolts and balanceshaft.

  38. REMOVE NO. 2 BALANCESHAFT DRIVEN GEAR


    1. A00JXZ5E01

      Mount the balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

    2. Remove the bolt, balanceshaft driven gear and balanceshaft thrust washer.

  39. REMOVE REAR ENGINE OIL SEAL RETAINER

    A00JWREE01

    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.

  40. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A00JZW9E01

      Using a screwdriver and hammer, tap out the oil seal.

  41. REMOVE SUPPLY PUMP OIL SEAL


    1. A00K01SE01

      Using a screwdriver and hammer, tap out the oil seal.

  42. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A00K0WYE01

      Using a screwdriver and hammer, tap out the oil seal.