ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

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

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

PROCEDURE

  1. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

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  2. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

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  3. REMOVE NO. 1 NOZZLE HOLDER CLAMP

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  4. REMOVE INJECTOR ASSEMBLY

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  5. REMOVE CAMSHAFT POSITION SENSOR

    1. A271548

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR

    1. A271549

      Detach the clip and disconnect the crankshaft position sensor harness.

    2. Remove the 2 bolts and crankshaft position sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  8. REMOVE ENGINE WATER PUMP ASSEMBLY

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  9. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  10. REMOVE OIL COOLER ASSEMBLY

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  11. REMOVE NO. 1 OIL COOLER BRACKET

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  12. REMOVE ENGINE OIL LEVEL SENSOR

    1. A263730

      Remove the 4 bolts and engine oil level sensor.

  13. REMOVE WATER INLET HOUSING

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  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  17. REMOVE OIL FILTER ELEMENT

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  18. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

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  19. REMOVE OIL FILTER BRACKET

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  20. REMOVE OIL STRAINER SUB-ASSEMBLY

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  21. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A202382C06

      *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. A202383C03

      *1

      Matchmark

      *2

      Timing Mark

      Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tip:

      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.

      Tip:

      The timing chain 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. A202384N02

      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.

  22. REMOVE CRANKSHAFT PULLEY

    1. A297923N01

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt.

      09213-58014

      91551-80840

      09330-00021

    2. A201752E01

      Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

      09950-50013

      09951-05010

      09952-05010

      09953-05020

      09954-05021

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  24. REMOVE FRONT CRANKSHAFT OIL SEAL

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  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A300900C01

      *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.

      09240-00020

      09242-00200

    3. A202387

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

  26. REMOVE CHAIN TENSIONER SLIPPER

    A202388

  27. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A202389

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

  28. REMOVE CAMSHAFT TIMING SPROCKET

    1. A271551

      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. A202391

      Remove the oil pump drive gear from the crankshaft.

  30. REMOVE CRANKSHAFT TIMING SPROCKET

    1. A202392

      Remove the crankshaft timing sprocket from the crankshaft.

  31. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY

    1. A202393

      Remove the 2 crankshaft pulley set crankshaft keys from the crankshaft.

  32. REMOVE CAMSHAFT

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

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  34. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  35. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  36. REMOVE CYLINDER HEAD GASKET

  37. REMOVE REAR ENGINE OIL SEAL

    Click hereClick here

  38. REMOVE OIL BAFFLE PLATE

    1. A129588

      Remove the 4 bolts and oil baffle plate.

  39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    1. A263734

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