ENGINE UNIT (w/o 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 NOZZLE HOLDER SEAL


    1. A00XD84E01

      Using a small screwdriver, remove the 4 holder seals by prying between each holder seal and the cutout part of the cylinder head cover.

  3. 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. A00XINNE01

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

    2. A00XCKH

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

  4. REMOVE INJECTOR ASSEMBLY


    1. A00XEY5E04
      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. A00XGHLE01

      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.

  5. REMOVE CAMSHAFT TIMING PULLEY


    1. A00XEISE01

      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.

  6. REMOVE NO. 2 TIMING BELT COVER


    1. A00XDLI

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

  7. REMOVE CYLINDER BLOCK INSULATOR


    1. A00XC1L

      Remove the cylinder block insulator from the cylinder head.

  8. REMOVE CAMSHAFT


    1. A00XJ4QE03
      Text in Illustration
      *1 Key Groove

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

    2. A00XKKZE01

      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.

  9. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  10. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00XJRXE01

      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.

      Tech Tips

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

      Note

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

  11. REMOVE CYLINDER HEAD GASKET

  12. REMOVE WATER PUMP ASSEMBLY


    1. A00JUIH

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

  13. 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. A00K16QE01

      Remove the 14 bolts and 2 nuts.

    2. A00JZ91E01

      Pry the gear cover at the locations shown in the illustration, and remove the gear cover together with the injection gear.

      Note

      Be careful not to drop the injection gear.

    3. A00JV44

      Remove the O-ring from the timing gear case.

  14. 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.

  15. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00JZDQE01

      Remove the No. 1 crankshaft position sensor plate.

  16. REMOVE CRANKSHAFT TIMING GEAR


    1. A00JXF2E01

      Using SST, remove the crankshaft timing gear.

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

  17. REMOVE IDLE GEAR THRUST PLATE


    1. A00JV12E01

      Remove the 2 bolts and thrust plate.

  18. REMOVE NO. 1 IDLE GEAR


    1. A00K1MNE01

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

  19. 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.

  20. 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.

  21. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A00K16NE01

      Remove the idle gear shaft.

  22. 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.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00K0EM

      Remove the 2 nuts, oil strainer and gasket.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00JW3T

      Remove the 22 bolts and 2 nuts.

    2. A00JZWIE01
      Text in Illustration
      *A LH Side
      *B RH Side
      *1 Pry

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A00JXGA

      Remove the gasket.

  25. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A00JU79E01

      Remove the union bolt and 8 bolts.

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

    3. Remove the 2 O-rings.

  26. 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 would still be more than the maximum clearance, replace the No. 1 baranceshaft sub-assembly.

  27. REMOVE NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. A00K0NEE01

      Remove the 2 bolts and balanceshaft.

  28. 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.

  29. 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 would still be more than the maximum clearance, replace the No. 2 baranceshaft sub-assembly.

  30. REMOVE NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. A00JV69E01

      Remove the 2 bolts and balanceshaft.

  31. 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, balance shaft driven gear and balanceshaft thrust washer.

  32. REMOVE REAR ENGINE OIL SEAL RETAINER

    A00JWREE01

    1. Remove the 5 bolts.

    2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and cylinder block.

  33. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A00JZW9E01

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

  34. REMOVE SUPPLY PUMP OIL SEAL


    1. A00K01SE01

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

  35. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A00K0WYE01

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