ENGINE UNIT(w/ Glow Plug Controller) DISASSEMBLY

PROCEDURE

  1. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click hereClick here

  2. REMOVE WATER OUTLET SUB-ASSEMBLY

    1. A348765

      Remove the 3 bolts, 2 nuts and water outlet sub-assembly from the cylinder head sub-assembly.

    2. A348766

      Remove the water outlet gasket from the cylinder head sub-assembly.

  3. REMOVE WATER INLET

    1. A348767

      Remove the 3 bolts and water inlet from the water inlet housing.

    2. A349648

      Remove the No. 1 water inlet housing gasket from the water inlet.

  4. REMOVE OIL PRESSURE SENDER GAGE ASSEMBLY

    Click here

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

    1. A348776

      Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

    2. A348777

      Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A348769

      Remove the 11 bolts, nut and cylinder head cover sub-assembly from the cylinder head sub-assembly.

    2. A349647

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  7. REMOVE ENGINE MOUNTING BRACKET RH

    1. A348770

      Remove the 4 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.

  8. REMOVE NO. 2 TIMING CHAIN COVER

    1. A348771

      Remove the bolt and manifold temperature sensor bracket from the timing chain cover sub-assembly.

    2. Remove the No. 2 timing chain cover from the timing chain cover sub-assembly.

  9. REMOVE CAMSHAFT POSITION SENSOR

    1. A348772

      Remove the bolt and camshaft position sensor from the timing chain cover sub-assembly.

      Note:

      If a component has been dropped or subjected to a strong impact, replace the camshaft position sensor.

  10. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

  11. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    1. A348773

      Remove the bolt and oil pressure switching valve assembly from the timing chain cover sub-assembly.

      Note:

      If a component has been dropped or subjected to a strong impact, replace the oil pressure switching valve assembly.

    2. A348774

      Remove the 20 bolts and 2 nuts.

    3. A348778C01

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover sub-assembly by prying between the cylinder head sub-assembly and cylinder block sub-assembly.

      Note:

      Do not damage the contact surfaces of the timing chain cover sub-assembly, cylinder head sub-assembly and cylinder block sub-assembly.

    4. A348780

      Remove the oil pump gasket from the oil pan sub-assembly.

  12. REMOVE TIMING CHAIN COVER OIL SEAL

    1. A348781C01

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover oil seal from the timing chain cover sub-assembly.

  13. REMOVE OIL CHECK VALVE SUB-ASSEMBLY

    1. A348782

      Using a 5 mm hexagon wrench, remove the bolt and oil check valve sub-assembly from the timing chain cover sub-assembly.

  14. REMOVE WATER INLET HOUSING

    1. A348783

      Remove the 3 bolts and water inlet housing from the timing chain cover sub-assembly.

    2. A349646

      Remove the No. 2 water inlet housing gasket from the inlet water housing.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note:

    Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.

    1. A348784C01

      *a

      Plunger

      *b

      Groove

      *c

      Hole
      V100135

      Push

      Push in the plunger until the groove is aligned with the hole, and then insert a 1.1 mm (0.0433 in.) diameter bar.

    2. A348785

      Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder block sub-assembly.

  16. REMOVE CHAIN TENSIONER SLIPPER

    1. A348786

      Remove the chain tensioner slipper from the cylinder head sub-assembly.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A348787

      Using an 8 mm socket hexagon wrench, remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.

  18. REMOVE CHAIN SUB-ASSEMBLY

    1. A348788N01

      Using SST, hold the camshaft timing sprocket.

      09960-10010

      09962-01000

      09963-01000

    2. Remove the 3 bolts and sensor plate.

    3. A348789

      Remove the camshaft timing sprocket, crankshaft timing sprocket and chain sub-assembly together.

  19. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    1. A348790

      Remove the chain tensioner plate with the chain damper spring from the pin.

    2. A348791

      Insert a 4 mm (0.157 in.) diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

    3. A348792

      Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly together.

  20. REMOVE CHAIN DAMPER SPRING

    1. A198518

      Remove the chain damper spring from the chain tensioner plate.

  21. REMOVE CAMSHAFT

    Click here

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

    1. G035812

      Remove the 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

  23. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    1. A348793N01

      Loosen and remove the 10 cylinder head set bolts and 10 cylinder head set plate washers in several steps in the order shown in the illustration.

      Note:

      • When removing the cylinder head set bolts, do not drop the plate washers into the engine.

      • Removing the cylinder head set bolts in the wrong order may cause damage to the cylinder head sub-assembly.

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

  24. REMOVE CYLINDER HEAD GASKET

    Click here

  25. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    1. A348794

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

  26. REMOVE OIL FILTER ELEMENT

    Click here

  27. REMOVE OIL COOLER ASSEMBLY

    1. A348796C01

      *a

      Nut and Plate Washer

      Remove the 2 bolts, 2 nuts, 2 plate washers and oil cooler assembly from the oil filter bracket sub-assembly.

    2. A348797

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

  28. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    1. A348798

      Remove the 2 bolts and oil filter bracket sub-assembly from the oil pan sub-assembly.

    2. A348799

      Remove the oil filter bracket gasket from the oil pan sub-assembly.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    1. A348800

      Remove the oil pan drain plug and oil pan drain plug gasket from the No. 2 oil pan sub-assembly.

    2. Remove the 10 bolts and 2 nuts.

    3. A348801C01

      *a

      Oil Pan Seal Cutter

      Insert the oil pan seal cutter blade between the oil pan sub-assembly and No. 2 oil pan sub-assembly, and cut off the applied sealer.

      Note:

      Do not damage the oil pan sub-assembly or No. 2 oil pan sub-assembly.

    4. Remove the No. 2 oil pan sub-assembly from the oil pan sub-assembly.

  30. REMOVE ENGINE OIL LEVEL SENSOR

    1. A200044

      Remove the 5 bolts and engine oil level sensor from the oil pan sub-assembly.

  31. REMOVE OIL PAN SUB-ASSEMBLY

    1. A348812

      Remove the 12 bolts.

    2. A348802C01

      *a

      Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the oil pan sub-assembly by prying between the cylinder block sub-assembly and oil pan sub-assembly.

      Note:

      • Do not apply excessive force when prying between the cylinder block sub-assembly and oil pan sub-assembly.

      • Do not damage the contact surface of the cylinder block sub-assembly and oil pan sub-assembly.

  32. REMOVE ENGINE REAR OIL SEAL

    1. A198495

      Remove the engine rear oil seal from the crankshaft and cylinder block sub-assembly.