ENGINE UNIT (for DPF) DISASSEMBLY

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. Disconnect the ventilation hose.

    3. A01DYWG

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    4. A01DV31

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  3. REMOVE INJECTOR ASSEMBLY


    1. A01DZ18E04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01E2JYE02

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  4. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  5. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and No. 2 timing belt cover.

  6. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  7. REMOVE CAMSHAFT


    1. A01DX0VE03
      Text in Illustration
      *1 Key Groove

      Turn the camshaft with a wrench so that the key groove of the camshaft faces upward.

    2. A01E0JJE01

      Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

    3. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.

  8. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  9. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01E1AUE01

      Uniformly loosen the 18 cylinder head bolts in several passes in the sequence shown in the illustration. Then remove the 18 cylinder head bolts and 18 washers.

      Note

      Head warpage or cracking could result from removing bolts in the incorrect order.

    2. Remove the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a workbench.

      Note

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

      Tech Tips

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

  10. REMOVE CYLINDER HEAD GASKET

  11. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

      Remove the 5 bolts, 2 nuts, water pump and gasket.

  12. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump.


    1. A01DX9G

      Remove the 14 bolts and 2 nuts.

    2. A01E1WE

      Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

      Note

      Be careful not to drop the injection gear.

    3. A01E1BB

      Remove the O-ring from the timing gear case.

  13. REMOVE INJECTION GEAR


    1. A01E1H8

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.

    2. A01E0AU

      Remove the injection gear.

  14. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01DYY9

      Remove the No. 1 crankshaft position sensor plate.

  15. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO OIL PUMP GEAR


    1. A01E1TCE01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.2 mm (0.0079 in.)

      If the gear backlash is more than the maximum, replace the crankshaft timing gear or timing gear case assembly.

  16. INSPECT BACKLASH OF CRANKSHAFT TIMING GEAR TO NO. 1 IDLE GEAR


    1. A01DWATE01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.2 mm (0.0079 in.)

      If the gear backlash is more than the maximum, replace the crankshaft timing gear or No. 1 idle gear.

  17. INSPECT NO. 1 IDLE GEAR THRUST CLEARANCE


    1. Install the timing gear case, No. 1 idle gear and camshaft timing gear.

    2. A01DZLNE01

      Using a dial indicator, measure the thrust clearance.

      Standard thrust clearance
      0.06 to 0.11 mm (0.0024 to 0.0043 in.)
      Maximum thrust clearance
      0.3 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the idle gear thrust plate. If necessary, replace the No. 1 idle gear or No. 1 idle gear shaft.

  18. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DVI0E01

      Using SST, remove the crankshaft timing gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  19. INSPECT BACKLASH OF INJECTION GEAR TO NO. 1 IDLE GEAR


    1. Install the fuel supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01DZIFE01

      Using SST, install the injection gear with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }
    3. A01E0T0E01

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.15 mm (0.0008 to 0.0060 in.)
      Maximum gear backlash
      0.2 mm (0.0079 in.)

      If the gear backlash is more than the maximum, replace the injection gear or No. 1 idle gear.

    4. A01DZIFE01

      Using SST, remove the nut and injection gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    5. Remove the 2 nuts and fuel supply pump.

  20. REMOVE IDLE GEAR THRUST PLATE


    1. A01E196

      Remove the 2 bolts and idle gear thrust plate.

  21. REMOVE NO. 1 IDLE GEAR


    1. A01DZHW

      Remove the No. 1 idle gear together with the No. 2 idle sub gear.

  22. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01DXLD

      Remove the No. 1 idle gear shaft.

  23. REMOVE NO. 2 IDLE SUB GEAR


    1. A01DV95E01

      Turn the No. 1 idle gear over and set it in a vise.

      Note

      Be careful not to damage the gear.

    2. A01E1X4E01

      Using snap ring pliers, remove the shaft snap ring.

    3. A01E0SHE05
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 2 idle sub gear and idle gear spring.

  24. REMOVE ENGINE OIL LEVEL SENSOR


    1. Remove the 4 bolts and engine oil level sensor.

  25. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 22 bolts and 2 nuts.

    2. A01DXTOE03

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing belt case, or for the area between the oil pan and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  26. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the 2 bolts, 2 nuts, oil strainer and gasket.

  27. REMOVE TIMING GEAR CASE ASSEMBLY


    1. Remove the bolt and No. 1 vacuum transmitting pipe.

    2. A01E17DE01

      Remove the union bolt and 8 bolts.

    3. Pry the timing gear case at the location shown in the illustration and remove the gear case and gasket.

    4. A01E2GZE03

      Remove the 2 O-rings.

  28. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A01DZ9XE01

      Remove the 5 bolts.

    2. Using a screwdriver, remove the rear engine oil seal retainer by prying between the rear engine oil seal retainer and cylinder block.

  29. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01DWJQE01

      Using a screwdriver and hammer, tap out the oil seal.

  30. REMOVE SUPPLY PUMP OIL SEAL


    1. A01DWGME01

      Using a screwdriver and hammer, tap out the oil seal.

  31. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01E01XE01

      Using a screwdriver and hammer, tap out the oil seal.

  32. REMOVE CYLINDER BLOCK OIL ORIFICE

  33. INSPECT CONNECTING ROD THRUST CLEARANCE

    A01DX8YE01

    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.100 to 0.300 mm (0.0039 to 0.0118 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

  34. INSPECT CONNECTING ROD OIL CLEARANCE


    1. A01E0Y8E07
      Text in Illustration
      *1 Matchmark

      Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

    2. Remove the 2 connecting rod cap bolts.

    3. A01E1W3E01

      Using the 2 removed connecting rod bolts, move the connecting rod cap back and forth to remove the connecting rod cap.

    4. Remove the lower bearing from the connecting rod cap.

      Tech Tips

      Keep the lower bearing and connecting rod cap together.

    5. Clean the crank pin and bearings.

    6. Check the crank pin and bearings for pitting and scratches.

      If the crank pin or a bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    7. A01DWM9E03
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across the crank pin.

    8. A01E0Y8E08
      Text in Illustration
      *1 Matchmark

      Install the connecting rod cap Click here.

      Note

      Do not turn the crankshaft.

    9. Remove the 2 bolts, connecting rod cap and lower bearing.

    10. A01E01ZE03
      Text in Illustration
      *1 Plastigage
      A01E0XFE03
      Text in Illustration
      *1 Mark 1, 2 or 3
      *2 Mark 2, 3 or 4
      *3 No. 1
      *4 No. 2
      *5 No. 3
      *6 No. 4

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      STD 0.036 to 0.054 mm (0.0014 to 0.0021 in.)
      U/S 0.25, U/S 0.50 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum oil clearance
      0.1 mm (0.0039 in.)

      If the oil clearance is more than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

      Tech Tips

      If using a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the crankshaft and connecting rod cap, and then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      Item Number Mark
      Connecting rod cap 1 2 3
      Crankshaft 1 2 3 1 2 3 1 2 3
      Bearing to be used 2 3 4 3 4 5 4 5 6

      EXAMPLE:

      Connecting rod cap 3 + Crankshaft 1 =

      Total number 4 (Use bearing 4)

      Reference
      Standard Connecting Rod Big End Inside Diameter
      Item Specified Condition
      Mark 1 62.014 to 62.020 mm (2.4415 to 2.4417 in.)
      Mark 2 62.020 to 62.026 mm (2.4417 to 2.4420 in.)
      Mark 3 62.026 to 62.032 mm (2.4420 to 2.4422 in.)
      Standard Crank Pin Diameter
      Item Specified Condition
      Mark 1 58.994 to 59.000 mm (2.3226 to 2.3228 in.)
      Mark 2 58.988 to 58.994 mm (2.3224 to 2.3226 in.)
      Mark 3 58.982 to 58.988 mm (2.3221 to 2.3224 in.)
      Standard Sized Connecting Rod Bearing Center Wall Thickness
      Item Specified Condition
      Mark 2 1.486 to 1.489 mm (0.0585 to 0.0586 in.)
      Mark 3 1.489 to 1.492 mm (0.0586 to 0.0587 in.)
      Mark 4 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
      Mark 5 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
      Mark 6 1.498 to 1.501 mm (0.0590 to 0.0591 in.)

    11. Completely remove the Plastigage.

  35. REMOVE PISTON AND CONNECTING ROD


    1. A01E0ILE06
      Text in Illustration
      *1 Ridge Reamer

      Using a ridge reamer, remove all the carbon from the top of the cylinder.

    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block to remove them.

    3. Remove the upper bearing from the connecting rod.

      Tech Tips


      • Keep the bearings, connecting rod and cap together.

      • Be sure to organize the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

  36. REMOVE CONNECTING ROD BEARING SET


    1. Remove the connecting rod bearings from the connecting rods and connecting rod caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  37. REMOVE PISTON RING SET


    1. A01E2DU

      Using a piston ring expander, remove the 2 piston rings.

      Tech Tips

      Be sure to organize the removed piston rings in such a way that they can be reinstalled exactly as before.

    2. Remove the coil and oil ring by hand.

  38. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A01E2PE

      Using a small screwdriver, pry out the 2 snap rings from the piston.

    2. Gradually heat the piston to approximately 80°C (176°F).

    3. A01E0HUE01

      Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

      Tech Tips


      • The piston and pin are a matched set.

      • Be sure to organize the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

  39. INSPECT CRANKSHAFT THRUST CLEARANCE

    A01DWAFE01

    1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.04 to 0.24 mm (0.0016 to 0.0094 in.)
      Maximum thrust clearance
      0.3 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the thrust washers as a set.

      Standard Thrust Washer Thickness
      Item Specified Condition
      STD 2.430 to 2.480 mm (0.0957 to 0.0976 in.)
      O/S 0.125 2.555 to 2.605 mm (0.1006 to 0.1026 in.)
      O/S 0.250 2.680 to 2.730 mm (0.1055 to 0.1074 in.)

  40. INSPECT CRANKSHAFT OIL CLEARANCE


    1. A01DVTVE09

      Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.

    2. A01DVBHE01

      Using the removed crankshaft bearing cap bolts, pry the cap back and forth and remove the crankshaft bearing caps, lower crankshaft bearings and lower thrust washers (No. 5 crankshaft bearing cap only).

      Tech Tips


      • Keep the lower bearing and crankshaft bearing cap together.

      • Be sure to organize the bearing caps and lower thrust washers (No. 5 crankshaft bearing only) in such a way that they can be reinstalled exactly as before.

    3. Lift out the crankshaft.

    4. Clean each main journal and bearing.

    5. Check each crankshaft journal and bearing for pitting and scratches.

      If a journal or one of its bearings is damaged, replace the bearings for that journal. If necessary, grind or replace the crankshaft.

    6. Place the crankshaft on the cylinder block.

    7. A01DX71E02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each journal.

    8. Install the crankshaft bearing caps Click here.

      Note

      Do not turn the crankshaft.

    9. Remove the crankshaft bearing caps.

    10. A01E18OE02
      Text in Illustration
      *1 Plastigage
      A01DWJBE02
      Text in Illustration
      *1 Front
      *2 Mark 2, 3, 4, 5 or 6
      *3 No. 1
      *4 No. 2
      *5 No. 3
      *6 No. 4
      *7 No. 5

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      STD 0.030 to 0.048 mm (0.0012 to 0.0019 in.)
      O/S 0.25, O/S 0.50 0.037 to 0.077 mm (0.0015 to 0.0030 in.)
      Maximum oil clearance
      0.1 mm (0.0039 in.)

      If the oil clearance is more than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

      Tech Tips

      If replacing the cylinder block sub-assembly, the bearing oil clearance will be within the standard range.

      Standard oil clearance
      0.030 to 0.048 mm (0.0012 to 0.0019 in.)

      Tech Tips

      If using a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 2, 3, 4, 5 and 6.

      Item Number Mark
      Cylinder block 1 2 3
      Crankshaft 1 2 3 1 2 3 1 2 3
      Bearing to be used 2 3 4 3 4 5 4 5 6

      EXAMPLE:

      Cylinder block 2 + crankshaft 1 =

      Total number 3 (Use bearing 3)

      Reference
      Standard Cylinder Block Main Journal Bore Diameter
      Item Specified Condition
      Mark 1 75.000 to 75.006 mm (2.9528 to 2.9530 in.)
      Mark 2 75.006 to 75.012 mm (2.9530 to 2.9532 in.)
      Mark 3 75.012 to 75. 018 mm (2.9532 to 2.9535 in.)
      Standard Crankshaft Journal Diameter
      Item Specified Condition
      Mark 1 69.994 to 70.000 mm (2.7557 to 2.7559 in.)
      Mark 2 69.988 to 69.994 mm (2.7554 to 2.7557 in.)
      Mark 3 69.982 to 69.988 mm (2.7552 to 2.7554 in.)
      Standard Sized Main Bearing Center Wall Thickness
      Item Specified Condition
      Mark 2 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
      Mark 3 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
      Mark 4 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
      Mark 5 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
      Mark 6 2.494 to 2.497 mm (0.0982 to 0.0983 in.)

    11. Completely remove the Plastigage.

  41. REMOVE CRANKSHAFT


    1. Lift out the crankshaft.

    2. Remove the upper bearings and upper thrust washers (No. 5 crankshaft bearing only) from the cylinder block.

      Tech Tips

      Arrange the bearing caps, bearings and thrust washers (No. 5 crankshaft bearing only) in the correct order.

  42. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Remove the 4 check valves and 4 oil nozzles.

  43. REMOVE STUD BOLT

    Tech Tips

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


    1. Remove the stud bolts.