ENGINE UNIT DISASSEMBLY

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A00OU78E01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    2. Remove the bolt and No. 2 nozzle leakage pipe.

  2. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A00OV7L

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  3. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A00OQG9

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  4. REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector.

      Note

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A00ORUE

      Remove the bolt and sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00OV5C

      Remove the clip and disconnect the sensor harness.

    2. Remove the 2 bolts and crankshaft position sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A00OVCUE01

      Using SST, remove the sensor and gasket.

      SST
      09817-33190

  8. REMOVE WATER PUMP ASSEMBLY


    1. A003DRL

      Remove the 7 bolts, water pump and gasket.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the engine oil pressure switch connector.

    2. A00E8EYE01

      Using SST, remove the engine oil pressure switch.

      SST
      09224-00010

  10. REMOVE OIL COOLER ASSEMBLY


    1. A00OVUH

      Remove the 5 bolts and oil cooler.

    2. Remove the 3 O-rings from the oil cooler bracket.

  11. REMOVE NO. 1 OIL COOLER BRACKET


    1. A00OV34

      Remove the 6 bolts, nut and No. 1 oil cooler bracket.

      Text in Illustration
      A00OVAR Nut

    2. Remove the 3 O-rings from the No. 1 oil cooler bracket.

  12. REMOVE ENGINE OIL LEVEL SENSOR


    1. A00OVF6

      Remove the 4 bolts and sensor.

  13. REMOVE WATER INLET HOUSING


    1. A00OQNF

      Remove the 3 nuts, gasket and water inlet housing.

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00OVQG

      Remove the 4 nozzle holder clamp seats, 14 bolts, nut and cylinder head cover.

      Text in Illustration
      A00OV9Z Bolt
      A00OVAR Nozzle Holder Clamp Seat
      A00OVPJ Nut
    2. A00OT0Y

      Remove the cylinder head cover gasket from the cylinder head cover.

  16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00OTUB

      Remove the 18 bolts and 2 nuts.

      Text in Illustration
      A00OVAR Nut
    2. A00OQGJE06

      Insert the blade of an oil pan seal cutter between the No. 2 oil pan and cylinder block, cut through the applied sealer and remove the No. 2 oil pan.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing chain cover.

      • Be careful not to damage the contact surfaces of the No. 2 oil pan.

  17. REMOVE OIL FILTER ELEMENT


    1. A00OVMC

      Remove the oil filter drain plug.

    2. Remove the O-ring from the oil filter drain plug and install it to an oil filter drain pipe.

    3. A00OSJ5E01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Drain Pipe

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

    4. Remove the oil filter drain pipe.

    5. Apply a light coat of engine oil to a new O-ring and install it to the oil filter drain plug.

    6. Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    7. A00OV5WE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    8. A00OUSIE01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Be sure to remove the cap O-ring by hand without using any tools to prevent damage to the cap O-ring groove.

  18. REMOVE OIL FILTER BRACKET


    1. A00OSI5

      Remove the 4 bolts and oil filter bracket.

    2. A00OVJR

      Remove the gasket from the oil filter bracket.

  19. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00OU5S

      Remove the 3 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  20. REMOVE CRANKSHAFT PULLEY


    1. Set the No. 1 piston to TDC/compression.


      1. A00OVCCE01
        Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark

        Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.

    2. A00OSC1E01
      Text in Illustration
      *1 Matchmark
      *2 Timing Mark

      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).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tech Tips

      The timing chain has 2 yellow-colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A00OT6SE01

      Turn the crankshaft by approximately 90° in the direction of engine revolution from the point where the No. 1 piston is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

    5. A00OQDQE01

      Using SST, remove the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A00OS3NE01

      Using SST, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00ORM9

      Remove the 13 bolts and seal washer.

      Text in Illustration
      A00OVAR Bolt and Seal Washer
    2. A00OTKY

      Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A00OTIYE01
      Text in Illustration
      *1 Gasket
      *2 O-Ring

      Remove the gasket and O-ring from the timing chain cover.

  22. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A00OT6O

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00OUC1E01
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner.

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )
    3. A00OQP5

      Remove the 2 bolts and No. 1 chain tensioner.

  24. REMOVE CHAIN TENSIONER SLIPPER

    A00OW3X

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A00ORKS

      Remove the 2 bolts and No. 1 chain vibration damper.

  26. REMOVE CAMSHAFT TIMING SPROCKET


    1. A00OQJ5

      Remove the 4 bolts from the sprocket while holding the hexagonal portion of the No. 2 camshaft with a wrench.

    2. Remove the camshaft timing sprocket and chain.

  27. REMOVE OIL PUMP DRIVE GEAR


    1. A00OQJF

      Remove the oil pump drive gear from the crankshaft.

  28. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A00OVP9

      Remove the crankshaft timing sprocket.

  29. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. A00OUGT

      Remove the 2 keys from the crankshaft.

  30. REMOVE CAMSHAFT


    1. A00OS88

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

    2. A00OTVGE01
      Text in Illustration
      *1 Oil Pipe Seat
      *2 No. 4 Bearing Cap

      Remove the 2 oil pipe seats.

    3. Uniformly loosen the 20 bolts in several steps in the sequence shown in the illustration and remove the bolts.

    4. Remove the 8 No. 3 bearing caps and No. 1 bearing cap.

      Tech Tips

      Do not remove the No. 4 bearing cap.

    5. Remove the camshaft and No. 2 camshaft.

    6. A00OR8P

      Remove the No. 2 camshaft bearing cap.

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


    1. A00OR67

      Remove the 16 No. 1 valve rocker arms.

  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A00OVEA

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  33. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00OUDJE01

      Uniformly loosen the 10 bolts in several steps, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note

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

  34. REMOVE CYLINDER HEAD GASKET

  35. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A00OR1CE05
      Text in Illustration
      *1 Cut Position

      Using a knife, cut off the lip of the rear crankshaft oil seal.

    2. Using a screwdriver, pry out the rear crankshaft oil seal.

      Note

      Be careful not to damage the crankshaft.

  36. REMOVE OIL BAFFLE PLATE


    1. A00OVHW

      Remove the 2 bolts and oil baffle plate.

  37. REMOVE ENGINE BALANCER ASSEMBLY


    1. A00OVEME01
      Text in Illustration
      *1 Service Bolt

      Align the timing marks (1 dot mark each) of the drive and driven gears by turning the crankshaft with a wrench.

    2. Put matchmarks on the drive gear and driven gear.

    3. Install a service bolt.

      Recommended Service Bolt
      Item Specified Condition
      Thread diameter 6 mm (0.236 in.)
      Thread pitch 1 mm (0.0394 in.)
      Bolt length 16 to 18 mm (0.630 to 0.709 in.)
      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

      Tech Tips

      When removing the balancer, make sure that the torsional spring force of the sub gear has been eliminated by the installation of the service bolt.

    4. A00OT88E01

      Uniformly loosen the 8 bolts in several steps, in the sequence shown in the illustration.

    5. Remove the engine balancer.

  38. REMOVE CYLINDER BLOCK DRAIN COCK PLUG


    1. A00OW2G

      Remove the cylinder block drain cock plug from the cylinder block.