БЛОК ДВИГАТЕЛЯ РАЗБОРКА


  1. REMOVE NO. 1 ENGINE HANGER


    1. B007T7O

      Remove the 2 bolts and No. 1 engine hanger from the cylinder head sub-assembly.

  2. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. B007V3E

      Remove the No. 2 cylinder block insulator from the front No. 1 engine mounting bracket LH.

  3. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B007W4U

      Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.

  4. REMOVE NO. 3 CYLINDER BLOCK INSULATOR


    1. B007VWO

      Remove the No. 3 cylinder block insulator from the cylinder block sub-assembly.

  5. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. B007QO3

      Remove the 4 bolts and generator bracket sub-assembly from the cylinder head sub-assembly and timing chain case assembly.

  6. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. B007QHX

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  7. REMOVE ENGINE OIL COOLER SET


    1. B007P09

      Remove the 5 nuts and bolt from the engine oil cooler set.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut

    2. Remove the engine oil cooler set and water outlet pipe gasket from the cylinder block sub-assembly.

    3. B007SZR

      Remove the 2 O-rings from the cylinder block sub-assembly.

  8. REMOVE OIL FILTER SUB-ASSEMBLY


    1. B007PWME01

      Using SST, remove the oil filter sub-assembly.

      SST
      09228-07502

      Tech Tips


      • Before removing the oil filter sub-assembly, place cloth where the oil may splash.


      • Use a container to catch the draining engine oil.

  9. REMOVE OIL FILTER UNION


    1. B007PA2

      Using a 27 mm deep socket wrench, remove the oil filter union from the oil filter bracket.

  10. REMOVE OIL FILTER BRACKET


    1. B007W3R

      Remove the bolt, 2 nuts and oil filter bracket from the cylinder block sub-assembly.

    2. Remove the 2 O-rings from the cylinder block sub-assembly.

  11. REMOVE INJECTOR ASSEMBLY


    1. B007TDF

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

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

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

    3. Remove the O-ring from each injector assembly.

  12. REMOVE NOZZLE HOLDER GASKET


    1. B007QQT

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

  13. REMOVE CAMSHAFT POSITION SENSOR


    1. B007QAN

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  15. REMOVE OIL FILLER CAP GASKET


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

  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B007UOG

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut
      B007T7S Nozzle Holder Clamp Seat
    2. B007SGUE01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  17. REMOVE NO. 5 CYLINDER BLOCK INSULATOR


    1. B007QZ2

      Remove the No. 5 cylinder block insulator from the cylinder block sub-assembly.

  18. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. B007T8D

      Remove the No. 1 cylinder block insulator from the cylinder block sub-assembly.

  19. REMOVE CRANKSHAFT POSITION SENSOR HARNESS BRACKET


    1. B007SLS

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor harness bracket from the cylinder block sub-assembly.

  20. REMOVE CRANKSHAFT POSITION SENSOR

    B007OVD

    1. Remove the bolt and crankshaft position sensor from the rear oil seal retainer.

  21. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the engine oil level sensor connector.

    2. B007TS3

      Remove the 4 bolts and engine oil level sensor from the oil pan sub-assembly.

  22. REMOVE OIL PAN SUB-ASSEMBLY


    1. B007SYK

      Remove the 2 nuts and 23 bolts.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut
    2. B007VVO

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


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

      • Be careful not to damage the cylinder block sub-assembly flange.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B007RFC

      Remove the 5 bolts, oil strainer sub-assembly and gasket from the cylinder block sub-assembly.

  24. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B007SI7

      Remove the 5 bolts.

    2. B007VH8

      Remove the rear engine oil seal retainer by prying between the rear engine oil seal retainer and cylinder block sub-assembly with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE REAR ENGINE OIL SEAL


    1. B007PEBE01
      Text in Illustration
      *a Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

    2. Using a screwdriver, tap out the rear engine oil seal from the rear engine oil seal retainer.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B007U1M

      Remove the 8 bolts, engine water pump assembly and gasket from the timing chain case assembly.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

    2. B007P6ZE01
      Text in Illustration
      *a Timing Mark

      Align the timing mark of the crankshaft pulley and timing chain cover sub-assembly by rotating the crankshaft clockwise.

    3. 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).

  28. REMOVE TIMING CHAIN COVER PLATE

    B007UOY

    1. Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  29. REMOVE SUPPLY PUMP ASSEMBLY

    Note

    Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.

    B007UY5

    1. B007T89E01
      Text in Illustration
      *a Hold
      B007USN Turn

      Using SST, hold the crankshaft pulley and loosen the supply pump shaft nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      Note

      Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.

      Tech Tips

      Rotate the supply pump shaft nut once to loosen it.

    2. B007S55E01
      Text in Illustration
      *a Engine Front Side
      *b Engine Rear Side
      *c Hexagonal Portion

      Install SST to the timing chain cover sub-assembly with the 3 bolts.

      SST
      09241-11010
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips


      • Make sure that the installation direction of SST is as shown in the illustration.

      • B007TPDE01

        Align the hexagonal portion of SST with the supply pump shaft nut to install SST.

    3. B007S30

      Remove the 2 bolts and No. 1 fuel pump bracket from the cylinder block sub-assembly and supply pump assembly.

    4. B007VWW

      Loosen the 3 nuts to the ends of the stud bolts.

      Note

      Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.

    5. B007VQ4E01

      Using SST, loosen the supply pump shaft nut and detach the supply pump assembly and injection pump drive gear.

    6. Remove the 3 nuts from the stud bolts.

    7. Remove the O-ring from the supply pump assembly.

    8. Remove SST from the timing chain cover sub-assembly.

    9. B007P27

      Remove the supply pump shaft nut from the timing chain cover sub-assembly service hole.

    10. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

  30. REMOVE INJECTION PUMP INSULATOR


    1. B007SAN

      Remove the injection pump insulator from the cylinder block sub-assembly.

  31. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B007U1K

      Remove the 20 bolts from the timing chain cover sub-assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the points in the illustration.

      B007OC2E01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain cover sub-assembly and timing chain case assembly.

    3. B007WDC

      Remove the timing chain case gasket from the timing chain case assembly.

  32. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B007UX8E01
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pull out the front crankshaft oil seal.

      Note

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

  33. REMOVE OIL PUMP RELIEF VALVE PLUG


    1. B007QHK

      Remove the oil pump relief valve plug and gasket from the timing chain cover sub-assembly.

  34. INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR


    1. B007VM4

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.3 mm (0.000787 to 0.0118 in.)
      Maximum gear backlash
      0.42 mm (0.0165 in.)

      If the gear backlash is more than the maximum, replace the timing chain case assembly or oil pump drive gear.

  35. REMOVE OIL PUMP DRIVE GEAR


    1. B007SVR

      Remove the oil pump drive gear from the crankshaft.

  36. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 3 chain tensioner assembly, the plunger and 2 springs may come off of the No. 3 chain tensioner assembly body, but this is not a malfunction.

    • B007QXYE01

      Before installing the plunger and 2 springs to the No. 3 chain tensioner assembly body, check that they are free of foreign matter and not damaged.


    1. B007QUBE01
      Text in Illustration
      *a No. 3 Chain Tensioner Assembly Body
      *b Spring
      *c Plunger

      Fully insert the plunger, align the No. 3 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

    2. B007PO8
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Remove the 2 bolts, No. 3 chain tensioner assembly and gasket from the engine balancer assembly.

  37. REMOVE NO. 1 BALANCE SHAFT THRUST PLATE


    1. B007UTC

      Remove the bolt and No. 1 balance shaft thrust plate from the balance shaft gear sub-assembly.

  38. REMOVE BALANCE SHAFT TIMING SPROCKET, BALANCE SHAFT GEAR SUB-ASSEMBLY WITH NO. 3 CHAIN SUB-ASSEMBLY


    1. B007UGV

      Remove the balance shaft timing sprocket, balance shaft gear sub-assembly with No. 3 chain sub-assembly from the crankshaft and engine balancer assembly.

  39. REMOVE ENGINE BALANCER ASSEMBLY


    1. B007OUN

      Remove the 8 bolts and engine balancer assembly from the cylinder block sub-assembly.

  40. REMOVE TIMING CHAIN GUIDE


    1. B007UUA

      Remove the bolt and timing chain guide from the cylinder head sub-assembly.

  41. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B007UAXE01
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate clockwise to release the lock. Once the lock is released, push the plunger into the No. 2 chain tensioner assembly.

    2. B007R4ME01
      Text in Illustration
      *a Pin

      Move the stopper plate counter clockwise to set the lock, and then insert a pin into the stopper plate hole.

    3. B007UIH

      Remove the 2 bolts and No. 2 chain tensioner assembly from the timing chain case assembly.

  42. REMOVE NO. 2 CHAIN TENSIONER SLIPPER


    1. B007W1P

      Remove the bolt and No. 2 chain tensioner slipper from the timing chain case assembly.

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B007OQ6

      Remove the 2 bolts and No. 2 chain vibration damper from the timing chain case assembly.

  44. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. Remove the No. 2 chain sub-assembly from the camshaft timing sprockets and injection pump drive gear.

  45. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 1 chain tensioner assembly, the plunger and spring may come off of the No. 1 chain tensioner assembly body, but this is not a malfunction.

    • B007SLVE01

      Before installing the plunger and spring to the No. 1 chain tensioner assembly body, check that they are free of foreign matter and not damaged.

    Text in Illustration
    *a No. 1 Chain Tensioner Assembly Body
    *b Spring
    *c Plunger

    1. B007UVRE01
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Fully insert the plunger, align the No. 1 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

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

  46. REMOVE NO. 1 CHAIN TENSIONER SLIPPER


    1. B007TRS

      Remove the No. 1 chain tensioner slipper from the straight pin.

  47. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B007OLR

      Remove the bolt and No. 1 chain vibration damper from the cylinder block sub-assembly.

  48. REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY


    1. B007TM1

      Remove the crankshaft timing sprocket, injection pump drive gear with No. 1 chain sub-assembly from the crankshaft and supply pump shaft.

  49. REMOVE CAMSHAFT TIMING SPROCKET


    1. for Exhaust Side:


      1. B007R2WE01
        Text in Illustration
        *a Hold
        B007USN Turn

        Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the No. 2 camshaft.

        Note

        Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

    2. for Intake Side:


      1. B007STWE01
        Text in Illustration
        *a Hold
        B007USN Turn

        Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the camshaft.

        Note

        Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

  50. REMOVE TIMING CHAIN CASE ASSEMBLY


    1. B007PU8

      Remove the 15 bolts from the timing chain case assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain case assembly by prying the points in the illustration.

      B007P4OE01
      Text in Illustration
      *a Protective Tape - -

      Note

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

    3. B007OFG

      Remove the 4 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.

    4. B007US2

      Remove the No. 2 water pump gasket from the timing chain case assembly.

  51. REMOVE NO. 3 CAMSHAFT BEARING CAP


    1. B007S02

      Remove the 2 camshaft bearing cap bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.

  52. REMOVE NO. 1 AND NO. 2 CAMSHAFT BEARING CAP


    1. B007SSJE01

      Remove the 20 camshaft bearing cap bolts in the sequence shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  53. REMOVE CAMSHAFT


    1. Remove the camshaft from the cylinder head sub-assembly.

  54. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the cylinder head sub-assembly.

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


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

  56. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

  57. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B007W0IE01

      Uniformly loosen the 10 cylinder head set bolts in several passes in the sequence shown in the illustration. Then remove the 10 cylinder head set bolts and 6 cylinder head set bolt spacers.

      Note


      • Cylinder head sub-assembly warpage or cracking could result from removing bolts in the incorrect order.

      • Be careful not to drop the cylinder head set bolt spacers into the cylinder head sub-assembly.

    2. Lift the cylinder head sub-assembly from the ring pins on the cylinder block sub-assembly, and place the cylinder head sub-assembly on wooden blocks on a bench.

      Note

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

      Tech Tips

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

  58. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block sub-assembly.

  59. REMOVE LOCK PLATE


    1. B007Q7X

      Remove the bolt and lock plate from the cylinder block sub-assembly.

  60. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

  61. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pin unless it is being replaced.