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. A01IU3ZE01
      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. A01ISYZ

      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. A01INWR

      Remove the 4 bolts, 4 washers and 4 No. 1 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 assembly.

      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. A01IQ1RE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01IRKEE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the clip and disconnect the crankshaft position sensor harness.

    2. Remove the 2 bolts and crankshaft position sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01IN8AE01

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  8. REMOVE WATER PUMP ASSEMBLY


    1. A01IS2Y

      Remove the 7 bolts, water pump assembly and gasket.

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (for CCo)


    1. Disconnect the engine oil pressure switch connector.

    2. A01IPDV

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

  10. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (for DPF)


    1. Disconnect the oil pressure sender gauge connector.

    2. A01IQY0

      Using a 27 mm deep socket wrench, remove the oil pressure sender gauge assembly.

  11. REMOVE OIL COOLER ASSEMBLY


    1. A01IRXA

      Remove the 5 bolts and oil cooler assembly.

    2. for CCo:

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

    3. for DPF:

      Remove the 3 gaskets from the No. 1 oil cooler bracket.

  12. REMOVE NO. 1 OIL COOLER BRACKET


    1. A01IU37E01
      Text in Illustration
      *A for CCo
      *B for DPF
      A01ISER Nut

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

    2. for CCo:

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

    3. for DPF:

      Remove the 3 gaskets from the No. 1 oil cooler bracket.

  13. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01INAI

      Remove the 4 bolts and engine oil level sensor.

  14. REMOVE WATER INLET HOUSING


    1. A01INGE

      Remove the 3 nuts, water inlet housing and gasket.

  15. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IN9G

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

      Text in Illustration
      A01ISM9 Bolt
      A01ISER Nozzle Holder Clamp Seat
      A01IQPE Nut
    2. A01IN7I

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

  17. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01IN6LE01
      Text in Illustration
      *A for CCo
      *B for DPF
      A01ISER Nut

      Remove the 18 bolts and 2 nuts.

    2. A01IPIFE06

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

      Note


      • Do not use the oil pan seal cutter for the area between the No. 2 oil pan sub-assembly and timing chain cover sub-assembly.

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

  18. REMOVE OIL FILTER ELEMENT


    1. A01INHEE08
      Text in Illustration
      *1 Oil filter drain pipe
      *2 Hose

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the oil filter drain pipe.

    2. A01IU62E01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the oil filter drain plug.

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

    4. A01IQO9E01
      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.

    5. Remove the oil filter drain pipe.

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

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

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

    8. Using SST, remove the oil filter cap.

      SST
      09228-06501
      A01IRTKE02
      Text in Illustration
      *A for CCo *B for DPF
    9. A01ITLEE01
      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.

  19. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY (for DPF)

  20. REMOVE OIL FILTER BRACKET


    1. A01INIDE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the 4 bolts and oil filter bracket.

    2. A01IS5LE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the gasket from the oil filter bracket.

  21. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01IPZE

      Remove the 3 bolts and oil strainer sub-assembly.

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

  22. REMOVE CRANKSHAFT PULLEY


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


      1. A01ITG4E01
        Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark

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

    2. A01IR1UE01
      Text in Illustration
      *A for CCo
      *B for DPF
      *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 chain sub-assembly has 2 colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A01IUJCE01

      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. A01IPB5E01

      Using SST, loosen the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A01IR03E01

      Using SST, remove the pulley bolt and crankshaft pulley.

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

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove the 13 bolts and seal washer.

      A01INA5E01
      Text in Illustration
      *A for CCo *B for DPF
      A01ISER Bolt and Seal Washer - -

    2. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      A01ITIEE01
      Text in Illustration
      *A for CCo *B for DPF

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block, stiffening crankcase and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01INE5E01
      Text in Illustration
      *A for CCo
      *B for DPF
      *1 Gasket
      *2 O-Ring

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

  24. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01ISUE

      Place the timing chain cover sub-assembly on wooden blocks.

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ITJ2E01
      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 assembly.

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

      SST
      09240-00020   ( 09242-00200 )
    3. A01IRKJ

      Remove the 2 bolts and No. 1 chain tensioner assembly.

  26. REMOVE CHAIN TENSIONER SLIPPER

    A01INFL

  27. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01ITAJ

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

  28. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01IN83E01
      Text in Illustration
      *A for CCo
      *B for DPF

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

    2. Remove the camshaft timing sprocket and chain sub-assembly.

  29. REMOVE OIL PUMP DRIVE GEAR


    1. A01IQAN

      Remove the oil pump drive gear from the crankshaft.

  30. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01IT2D

      Remove the crankshaft timing sprocket.

  31. REMOVE KEY


    1. A01INFK

      Remove the 2 keys from the crankshaft.

  32. REMOVE CAMSHAFT


    1. A01IU3D

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

    2. A01ITINE01
      Text in Illustration
      *1 Oil Pipe Seat
      *2 No. 4 Camshaft 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 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tech Tips

      Do not remove the No. 4 camshaft bearing cap.

    5. Remove the camshaft and No. 2 camshaft.

    6. A01ITJ0

      Remove the No. 2 camshaft bearing cap.

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


    1. A01IRYG

      Remove the 16 No. 1 valve rocker arm sub-assemblies.

  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01IT5U

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

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01IU50E01

      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.

  36. REMOVE CYLINDER HEAD GASKET

  37. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01IR5EE05
      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.

  38. REMOVE OIL BAFFLE PLATE


    1. A01ITCC

      Remove the 4 bolts and oil baffle plate.

  39. REMOVE CYLINDER BLOCK DRAIN COCK PLUG


    1. A01ISHU

      Remove the cylinder block drain cock plug from the cylinder block sub-assembly.