Engine Unit (W/O Dpf) Disassembly

w/ EGR Cooler:
Remove the 3 bolts and disconnect the 4 injector connectors.

w/o EGR Cooler:
Disconnect the 4 injector connectors.

Disconnect the ventilation hose.

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.

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

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

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

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

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

HINT:

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

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

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

NOTICE:

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

Remove the camshaft timing pulley.

Remove the 4 bolts, nut and timing belt cover.

Remove the cylinder block insulator from the cylinder head.

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

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

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

Remove the valve lifters.

HINT:

Arrange the valve lifters in the correct order.

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.

NOTICE:

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

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

NOTICE:

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

HINT:

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

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

Remove the 14 bolts and 2 nuts.

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

NOTICE:

Be careful not to drop the injection gear.

Remove the O-ring from the timing gear case.

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}

NOTICE:

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.

Remove the injection gear.

Remove the No. 1 crankshaft position sensor plate.

Using a dial indicator, measure the backlash.

Standard gear backlash:

0.02 to 0.15 mm (0.000787 to 0.00591 in.)

Maximum gear backlash:

0.2 mm (0.00787 in.)

Using a dial indicator, measure the backlash.

Standard gear backlash:

0.02 to 0.15 mm (0.000787 to 0.00591 in.)

Maximum gear backlash:

0.2 mm (0.00787 in.)

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

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance:

0.06 to 0.11 mm (0.00236 to 0.00433 in.)

Maximum thrust clearance:

0.3 mm (0.0118 in.)

Using SST, remove the crankshaft timing gear.

SST

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

Install the fuel supply pump with the 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

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}

Using a dial indicator, measure the backlash.

Standard gear backlash:

0.02 to 0.15 mm (0.000787 to 0.00591 in.)

Maximum gear backlash:

0.2 mm (0.00787 in.)

Using SST, remove the nut and injection gear.

SST

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

Remove the 2 nuts and fuel supply pump.

Remove the 2 bolts and idle gear thrust plate.

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

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

SST

09960-10010(09962-01000,09963-00700)

Text in Illustration

*1	Service Bolt
*2	No. 1 Idle Gear
*3	No. 2 Idle Sub Gear
	Turn

Using snap ring pliers, remove the snap ring.

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

Remove the No. 1 idle gear shaft.

Remove the 22 bolts and 2 nuts.

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.

NOTICE:

1. 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.
   
2. Be careful not to damage the oil pan flange.
   

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

Remove the bolt and No. 1 vacuum transmitting pipe.

Remove the union bolt and 8 bolts.

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

Remove the 2 O-rings.

Remove the 5 bolts.

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

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

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

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