ENGINE UNIT DISASSEMBLY

Note


  • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

  • When working on the fuel circuit, protect the generator assembly against dirt contamination. Cover generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

  • A01IPPME01

    After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

    SST
    PZ4TB-04941-79

  1. REMOVE CAMSHAFT POSITION SENSOR


    1. A01IUP4

      Disconnect the camshaft position sensor connector.

    2. Using an E6 "TORX" socket wrench, remove the bolt and camshaft position sensor.

  2. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01ISL6

      Using a T25 "TORX" socket wrench, remove the bolt.

    2. Disconnect the crankshaft position sensor connector and remove the crankshaft position sensor.

  3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01ITUM

      Disconnect the engine coolant temperature sensor connector.

    2. Using a 17 mm (12P) deep socket wrench, remove the engine coolant temperature sensor.

  4. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the engine oil pressure switch assembly connector.

    2. A01ISR4

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

    3. Remove the gasket.

  5. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01IQZ7

      Disconnect the connector and detach the 2 clamps to disconnect the wire harness Click here.

    2. Disconnect the nozzle leakage pipe assembly and remove the 4 sealing rings.


      1. A01IQKKE01
        Text in Illustration
        *1 Sealing Ring
        *2 Leakage Line
        *3 Clamp
        *4 Rubber Grommet
        *a Press
        *b Upward

        Press in the clamp.

        Note

        If a sealing ring is damaged, the entire leakage line of a cylinder group must be replaced.

      2. Detach the connection of the nozzle leakage pipe assembly upwards.

      3. Remove the sealing ring.

      4. Disconnect the nozzle leakage pipe assembly from the rubber grommet.

  6. REMOVE INJECTOR ASSEMBLY


    1. A01ISRF

      Disconnect the 4 injector assembly connectors.

    2. A01IRX9

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 4 centering rings.

    3. Remove the 4 clamping claws from the 4 injector assemblies.

    4. A01ITN6E01

      Remove the 4 injector assemblies from the cylinder head cover sub-assembly.


      1. Pull out the injector assembly with light rotational movements.

        SST
        PZ4TB-04942-79

        Tech Tips


        • If an injector assembly is stuck tight, mount SST (rod) to the pressure line connection.

        • Move injector assembly with SST (rod) only by a few degrees.

  7. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01IO7B

      Remove the 5 bolts, engine water pump assembly.

  8. REMOVE WATER BY-PASS PIPE


    1. A01IP3C

      Using a 5 mm hexagon socket wrench, remove the bolt and water by-pass pipe from the water inlet housing.

  9. REMOVE WATER INLET


    1. A01IQZC

      Remove the 4 bolts and water inlet together with the thermostat.

    2. Remove the gasket from the water inlet.

  10. REMOVE THERMOSTAT


    1. A01INLS

      Remove the thermostat.

  11. REMOVE WATER INLET HOUSING


    1. A01IOZP

      Using an E11 "TORX" socket wrench, remove the 5 bolts and water inlet housing.

  12. REMOVE WATER OUTLET


    1. A01ISO1

      Using an E10 "TORX" socket wrench, remove the 3 bolts and water outlet.

    2. Remove the gasket from the water outlet.

  13. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01IRZU

      Using a 27 mm socket wrench, remove the oil filter cover.

    2. A01IT3NE01
      Text in Illustration
      *1 Oil Filter Sub-assembly
      *2 Oil Filter Cover
      *3 O-Ring

      Remove the 2 O-rings from the oil filter sub-assembly and the oil filter cover.

      Note

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

    3. Remove the oil filter sub-assembly from the oil filter cover.

  14. REMOVE OIL FILTER ASSEMBLY


    1. A01IQ9N

      Remove the 6 bolts and oil filter assembly.

    2. A01ISKH

      Remove the gasket from the oil filter assembly.

  15. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01ISTL

      Remove the plug from the cylinder block.

    2. A01IQM6E01

      Set SST (A) to the plug hole of the cylinder block.

      SST(A)
      PZ4TB-04951-26
    3. A01IT6AE02
      Text in Illustration
      *1 Flywheel with Damper Assembly
      *a Groove

      Using SST (B), turn the crankshaft pulley clockwise until SST(A) fits into the groove of the flywheel with damper assembly.

      SST (B)
      PZ4TB-04933-80

    4. Using SST(A), hold the flywheel with damper assembly.

      SST (A)
      PZ4TB-04951-26

    5. Remove SST.

    6. Install the plug to the cylinder block.

  16. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01ISMT

      Using an E10 "TORX" socket wrench, loosen the 17 bolts and remove the cylinder head cover sub-assembly.

      Tech Tips

      Bolt cannot be removed from the cylinder head cover sub-assembly.

    2. A01INR9

      Remove the 5 gaskets from the cylinder head cover sub-assembly.

  18. HOLDING CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01IQV1E02
      Text in Illustration
      *a Mark E (Intake Side)
      *b Mark A (Exhaust Side)

      Check that the camshaft and No. 2 camshaft on the camshaft housing sub-assembly as shown in the illustration so that mark E and mark A face upward.

      Note

      If the marks of the camshaft and No. 2 camshaft are not at the positions shown in the illustration, perform set No. 1 cylinder to TDC again.

    2. A01IU2EE01
      Text in Illustration
      *a Timing Mark

      Check the camshaft and No. 2 camshaft timing marks.

    3. A01IUCME01
      Text in Illustration
      *a No Clearance

      Set SST and secure the camshaft and No. 2 camshaft.

      SST
      PZ4TB-04961-12

      Note

      Make sure there is no clearance between SST and the camshaft housing sub-assembly.

  19. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01ITHE

      Using a 24 mm socket wrench, remove the No. 2 chain tensioner assembly.

  20. REMOVE NO. 2 TIMING CHAIN GUIDE


    1. A01INY5

      Using a T45 "TORX" socket wrench, remove the bolt and No. 2 timing chain guide.

  21. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT


    1. A01IPNX

      Using an E10 "TORX" socket wrench, remove the 3 bolts and the camshaft timing sprocket.

      Note

      Do not drop the No. 2 chain sub-assembly into the gap between the cylinder block and timing chain cover plate.

    2. A01IQUP

      Suspend the No. 2 chain sub-assembly with a string or equivalent.

    3. Remove SST securing the camshaft and No. 2 camshaft.

    4. A01IO4HE01

      Using an E8 "TORX" socket wrench, uniformly loosen the 20 bolts 180° in several steps in the sequence shown in the illustration.

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

    6. Remove the 5 intake camshaft bearing caps and 5 exhaust camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    7. Remove the camshaft and No. 2 camshaft.

  22. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01ITFSE01

      Using an E10 "TORX" socket wrench, remove the 14 bolts and camshaft housing sub-assembly.

    2. A01IQRC

      Remove the 4 gaskets.

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


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

      Tech Tips

      Arrange the removed parts in the correct order.

  24. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

      Tech Tips

      Arrange the removed parts in the correct order.

  25. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01ISZN

      Using an E10 "TORX" socket wrench, remove the 5 bolts.

    2. A01IT19E01

      Using an E18 "TORX" socket wrench, uniformly loosen the 10 cylinder head bolts in several steps in the sequence shown in the illustration.

      Note

      Do not reuse the cylinder head bolt.

    3. Remove the 10 cylinder head bolts and cylinder head sub-assembly.

  26. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block.

  27. REMOVE CRANKSHAFT PULLEY


    1. A01ISTL

      Remove the plug from the cylinder block.

    2. A01IQM6E01

      Set SST (A) to the plug hole of the cylinder block.

      SST
      PZ4TB-04951-26
    3. A01IS2HE01
      Text in Illustration
      *a Groove

      Using SST (B), turn the crankshaft pulley clockwise until SST (A) fits into the groove of the flywheel with damper assembly.

      SST
      PZ4TB-04933-80

    4. Using SST (A), hold the flywheel with damper assembly.

    5. A01IO66

      Using an E10 "TORX" socket wrench, remove the 4 bolts and crankshaft pulley.

  28. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A01ISGXE01
      Text in Illustration
      *a Protective Tape

      Using a screw driver, pry out the timing gear case or timing chain case oil seal.

      Note

      Do not damage the oil seal press fit hole, crankshaft or the surface of the timing gear case or timing chain case.

      Tech Tips

      Tape the screw driver tip before use.

  29. REMOVE CLUTCH COVER ASSEMBLY


    1. A01IPBZE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt 180° at a time until the spring tension is released.

      Note

      Be sure to uniformly loosen the bolts 180° at a time according to the order in the illustration.

    3. Remove the set bolts and pull off the clutch cover to remove it.

      Note

      Do not drop the clutch disc.

  30. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, the pressure plate, and the surface of the flywheel away from oil and foreign matter.

  31. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY


    1. A01INASE01

      Using SST, fix the flywheel with damper assembly.

      SST
      PZ4TB-04939-38
    2. A01IRLNE01

      Using SST, remove the 8 bolts and flywheel with damper assembly.

      SST
      PZ4TB-04910-18

    3. Remove SST.

    4. A01IN3A

      Remove the crankshaft position sensor plate from the crankshaft.

  32. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01IRM9

      Remove the sealing cap from the timing chain cover plate.

    2. Remove the O-ring from the sealing cap.

    3. A01IU9ZE01

      Using SST B, install SST A to position the fuel supply pump assembly. Then remove SST B.

      SST
      PZ4TB-04967-25

      Note

      SST A remains in the timing chain cover plate until the end of the repair work.

    4. A01IN3T

      Remove the 4 bolts and fuel supply pump assembly support.

    5. A01IU94

      Remove the 2 bolts from the fuel supply pump assembly.

    6. A01ISMQE01
      Text in Illustration
      *1 Central Bolt

      Remove the screw connection between the fuel supply pump assembly and injection pump drive gear.

      Note


      • SST A remains in the timing chain cover plate.

      • The central bolt is supported on SST A until the fuel supply pump assembly pressed out.

      • A01IPCOE01

        The central bolt remains inside SST A attached to the injection pump drive gear.

    7. Remove the fuel supply pump assembly from the cylinder block.

  33. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01IPXI

      Remove the 4 bolts from the oil pan sub-assembly.

    2. A01IR4B

      Using an E10 "TORX" socket wrench, remove the 20 bolts from the oil pan sub-assembly.

    3. A01INA7

      Pry the oil pan sub-assembly at the locations shown in the illustration to remove the oil pan sub-assembly.

      Note

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

  34. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01IUDT

      Remove the 2 bolts and oil strainer sub-assembly.

  35. REMOVE OIL PUMP WITH VACUUM PUMP ASSEMBLY


    1. A01ITL6

      Using an E10 "TORX" socket wrench, remove the 4 bolts from the oil pump with vacuum pump assembly.

    2. A01IQ8S

      Remove the oil pump drive chain sub-assembly from the oil pump drive shaft gear, and then remove the oil pump with vacuum pump assembly.

      Tech Tips

      Do not drop the oil pump drive chain sub-assembly into the gap between the rear gear case and cylinder block.

    3. Suspend the oil pump drive chain with a string or equivalent.

  36. REMOVE REAR ENGINE OIL SEAL


    1. A01IRKNE01
      Text in Illustration
      *a Protective Tape

      Using a screw driver, pry out the rear engine oil seal.

      Note

      Do not damage the rear engine oil seal press fit hole, crankshaft or the surface of the timing chain cover plate.

      Tech Tips

      Tape the screw driver tip before use.

  37. REMOVE TIMING CHAIN COVER PLATE


    1. A01IRHC

      Using an E8 "TORX" socket wrench, remove the 11 bolts and timing chain cover plate.

  38. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. A01IP5S

      Remove the oil pump drive chain sub-assembly from the crankshaft.

  39. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01IQPW

      Remove the No. 2 chain sub-assembly from the injection pump drive gear.

  40. REMOVE NO. 2 TIMING CHAIN TENSION ARM


    1. A01ITXW

      Using a T45 "TORX" socket wrench, remove the bolt and No. 2 timing chain tension arm.

  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01IQKBE01
      Text in Illustration
      *a Hexagon Wrench

      Slowly push the plunger deep into the No. 1 chain tensioner assembly and insert a 3.0 mm hexagon wrench into the No. 1 chain tensioner assembly.

    2. A01IRWR

      Using an E8 "TORX" socket wrench, remove the 2 bolts and No. 1 chain tensioner assembly.

  42. REMOVE TIMING CHAIN TENSION ARM


    1. A01IPPL

      Using a T45 "TORX" socket wrench, remove the bolt and timing chain tension arm.

  43. REMOVE TIMING CHAIN GUIDE


    1. A01ISIP

      Using a T45 "TORX" socket wrench, remove the 2 bolts and timing chain guide.

  44. REMOVE INJECTION PUMP DRIVE GEAR


    1. A01IQU2

      Remove the injection pump drive gear and chain sub-assembly.

  45. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. A01IT0Z

      Using an E8 "TORX" socket wrench, remove the bolt and No. 2 oil nozzle sub-assembly.