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

    Click here

  2. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  3. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

  4. REMOVE INJECTOR ASSEMBLY

    Click here

  5. REMOVE CAMSHAFT POSITION SENSOR

    1. A266026

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR

    1. A202379

      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

    Click here

  8. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  10. REMOVE OIL COOLER ASSEMBLY

    Click here

  11. REMOVE NO. 1 OIL COOLER BRACKET

    Click here

  12. REMOVE ENGINE OIL LEVEL SENSOR

    1. A129585

      Remove the 4 bolts and engine oil level sensor.

  13. REMOVE WATER INLET HOUSING

    Click here

  14. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  17. REMOVE OIL FILTER ELEMENT

    Click here

  18. REMOVE OIL FILTER BRACKET

    Click here

  19. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  20. 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 crankshaft pulley with the timing pointer of the timing chain cover sub-assembly.

    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 cylinder 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 yellow-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 pulley by approximately 90° in the direction of engine revolution from the point where the No. 1 cylinder is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

  21. REMOVE CRANKSHAFT PULLEY

    1. A201753N05

      Using SST, loosen the crankshaft pulley bolt.

      09213-58014

      91551-80840

      09330-00021

    2. A201752N02

      Using SST, remove the bolt and crankshaft pulley.

      09950-50013

      09951-05010

      09952-05010

      09953-05020

      09954-05021

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  23. REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  24. 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.

  25. REMOVE CHAIN TENSIONER SLIPPER

    A202388

  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A202389

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

  27. REMOVE CAMSHAFT TIMING SPROCKET

    1. A266025

      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.

  28. REMOVE OIL PUMP DRIVE GEAR

    1. A202391

      Remove the oil pump drive gear from the crankshaft.

  29. REMOVE CRANKSHAFT TIMING SPROCKET

    1. A202392

      Remove the crankshaft timing sprocket from the crankshaft.

  30. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY

    1. A202393

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

  31. REMOVE CAMSHAFT

    Click here

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

    Click here

  33. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  34. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  35. REMOVE CYLINDER HEAD GASKET

  36. REMOVE REAR ENGINE OIL SEAL

    Click here

  37. REMOVE OIL BAFFLE PLATE

    1. A202405

      Remove the 2 bolts and oil baffle plate.

  38. REMOVE ENGINE BALANCER ASSEMBLY

    1. A202403C03

      *1

      Service Bolt

      *2

      Timing Mark

      Align the timing marks (1 dot mark each) of the drive and driven gears by turning the crankshaft with a wrench.

    2. Put matchmarks on the drive gear and driven gear.

    3. Install a service bolt.

      Recommended Service Bolt

      Item

      Specified Condition

      Thread diameter

      6 mm (0.236 in.)

      Thread pitch

      1 mm (0.0394 in.)

      Bolt length

      16 to 18 mm (0.630 to 0.709 in.)

      1.5 N*m

      15 kgf*cm

      13 in.*lbf

      Tip:

      When removing the balancer, make sure that the torsional spring force of the sub gear has been eliminated by the installation of the service bolt.

    4. A273384N03

      Uniformly loosen the 8 bolts in several steps, in the sequence shown in the illustration.

    5. Remove the engine balancer assembly.

  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.