Engine Unit Disassembly

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

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

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

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

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

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

Remove the 5 nuts and bolt from the oil cooler assembly.

Text in Illustration

	Bolt
	Nut

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

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

Using SST, remove the oil filter sub-assembly.

SST

09228-07501

HINT:

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

1. Use a container to catch the draining engine oil.
   

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

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

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

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

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

NOTICE:

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.

Remove the O-ring from each injector assembly.

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

Disconnect the camshaft position sensor connector.

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

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

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

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

	Bolt
	Nut
	Nozzle Holder Clamp Seat

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.

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

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

Disconnect the crankshaft position sensor connector.

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

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

Disconnect the engine oil level sensor connector.

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

Remove the 2 nuts and 11 bolts.

Text in Illustration

	Bolt
	Nut

Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly, cut off the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

1. Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.
   
2. Be careful not to damage the oil pan sub-assembly flange.
   

Remove the 2 nuts and 23 bolts.

Text in Illustration

	Bolt
	Nut

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.

NOTICE:

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

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

Remove the 5 bolts.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Place the rear engine oil seal retainer on wooden blocks.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the 8 bolts, engine water pump assembly and gasket.

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

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

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

HINT:

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).

Remove the 3 bolts and timing chain cover plate.

Remove the gasket.

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

SST

09213-58014(91551-80840)
09330-00021

Text in Illustration

*a	Hold
	Turn

NOTICE:

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

HINT:

Rotate the supply pump shaft nut once to loosen it.

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}

HINT:

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


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

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

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

NOTICE:

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

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

Remove the 3 nuts from the stud bolts.

Remove the O-ring from the supply pump assembly.

Remove SST from the timing chain cover sub-assembly.

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

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

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

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

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

NOTICE:

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

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

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

NOTICE:

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

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

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.)

Remove the oil pump drive gear from the crankshaft.

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.

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

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

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

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

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

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.

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.

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

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

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

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

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.

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

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

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

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

for Exhaust Side:

1. 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.
   

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

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

for Intake Side:

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

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

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

Remove the 15 bolts from the timing chain case assembly.

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

NOTICE:

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

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

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

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

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

HINT:

Arrange the removed parts in the correct order.

Remove the camshaft from the cylinder head sub-assembly.

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

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

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

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.

NOTICE:

1. Cylinder head sub-assembly warpage or cracking could result from removing bolts in the incorrect order.
   
2. Be careful not to drop the cylinder head set bolt spacers into the cylinder head sub-assembly.
   

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.

NOTICE:

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

HINT:

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.

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

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