ENGINE UNIT 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.


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE NOZZLE HOLDER SEAL


    1. Remove the 4 nozzle holder seals.

  3. 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. A01DXL9E02

      Disconnect the ventilation hose.

    2. Disconnect the 4 injector connectors.

    3. A01DXC5E01

      Using a small screwdriver, remove the 4 nozzle holder seals by prying the portion between each nozzle holder seal and the cutout part of the cylinder head cover.

    4. A01DZGHE01

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

    5. A01DV31

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

  4. REMOVE CAMSHAFT TIMING PULLEY

    A01DV9RE01

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

      Note

      Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

    2. Remove the camshaft timing pulley.

  5. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and timing belt cover.

  6. REMOVE CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    1. A01E2IC

      Remove the cylinder block insulator form the head.

  7. REMOVE INJECTOR ASSEMBLY


    1. A01E29AE01

      Remove the union bolt, 4 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 fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01DW1AE01

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

      Tech Tips

      Arrange the injectors, 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.

  8. REMOVE CAMSHAFT


    1. A01DX0VE02

      Face the key groove of the camshaft upward by turning the camshaft with a wrench.

    2. A01E0JJE01

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

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

  9. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A01E1AUE01

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

      Note

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

    2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

      Tech Tips

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

      Note

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

  10. REMOVE WATER PUMP ASSEMBLY

    A01DWA8

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

  11. REMOVE TIMING GEAR COVER


    1. A01DXBBE01

      Remove the 14 bolts and 2 nuts.

    2. A01E2E2E01

      Pry the gear cover at the locations shown in the illustration, and remove the gear cover together with the injection gear.

      Note

      Be careful not to drop the injection gear.

    3. A01E1BB

      Remove the O-ring from the timing gear case.

  12. 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.

  13. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01E15O

      Remove the No. 1 camshaft position sensor plate.

  14. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DVI0E01

      Using SST, remove the crankshaft timing gear.

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

  15. REMOVE IDLE GEAR THRUST PLATE


    1. A01E200

      Remove the 2 bolts and thrust plate.

  16. REMOVE NO. 1 IDLE GEAR


    1. A01DWM4

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

  17. REMOVE NO. 2 IDLE SUB GEAR


    1. A01E16CE02

      Using SST, turn the No. 2 idle sub gear clockwise and remove the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    2. A01DZYEE01

      Using snap ring pliers, remove the snap ring.

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

  18. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01DUY6

      Remove the idle gear shaft.

  19. REMOVE ENGINE OIL LEVEL SENSOR


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

  20. REMOVE OIL PAN SUB-ASSEMBLY

    A01E17BE04

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

    2. Remove the 22 bolts and 2 nuts.

    3. Insert the blade of a 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 a oil pan seal cutter for the timing belt case side and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  21. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  22. REMOVE TIMING GEAR CASE ASSEMBLY

    A01E17DE01

    1. Remove the union bolt and 8 bolts.

    2. Pry the gear case in the location shown in the illustration, and remove the gear case, driven rotor and gasket.

    3. Remove the 2 O-rings.

  23. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01DZ9XE01

      Remove the 5 bolts.

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

  24. REMOVE CYLINDER BLOCK OIL ORIFICE

  25. REMOVE PISTON AND CONNECTING ROD

    A01E0Y8E03

    1. 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, pry the connecting rod cap back and forth, and remove the connecting cap.

      Tech Tips

      Keep the lower bearing inserted with the connecting rod cap.

    4. Clean the crank pin and bearing.

    5. Check the crank pin and bearing for pitting and scratches.

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

    6. A01E0ILE01

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

    7. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

      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.

  26. REMOVE PISTON PIN


    1. A01E1JUE02

      Check the fit between the piston pin and connecting rod.


      1. Check that the piston moves smoothly.

        If the piston does not move smoothly, replace the piston pin and connecting rod.

    2. A01E2DU

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

      Tech Tips

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

    3. Remove the coil and oil ring by hand.

    4. Disconnect the connecting rod from the piston.


      1. A01E2PE

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

      2. A01DVLGE02

        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 and 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.

  27. REMOVE CRANKSHAFT SUB-ASSEMBLY


    1. A01DVTVE09

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

    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. 3 crankshaft bearing cap only).

      Tech Tips


      • Keep the lower crankshaft bearing and crankshaft bearing cap together.

      • Be sure to organize the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

    3. Lift out the crankshaft.

    4. Remove the upper bearings and upper thrust washers from the cylinder block.

      Tech Tips

      Arrange the main bearing caps, bearings and thrust washers in the correct order.

  28. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Remove the 4 check valves and oil nozzles.

  29. REMOVE NO. 1 HEAD STRAIGHT SCREW PLUG


    1. Remove the screw plug and gasket.