Engine Unit Disassembly

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

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.

HINT:

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

NOTICE:

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

Remove the union bolt, 4 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 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring and back-up ring from each injector.

Remove the 4 injection nozzle sheets from the cylinder head.

Remove the bolt of the camshaft timing pulley by 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.

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

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

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

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.

HINT:

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

NOTICE:

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

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

Remove the 14 bolts and 2 nuts.

Pry the gear cover in the locations shown in the illustration, and remove the gear cover together with the supply pump gear.

NOTICE:

Be careful not to drop the supply pump gear.

Remove the O-ring from the timing gear case.

Using SST, remove the injection gear.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

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:

0.20 mm (0.0079 in.)

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:

0.30 mm (0.0118 in.)

Secure the idle gears to the idle gear with the service bolt.

Remove the 2 bolts and thrust plate.

Turn the sub-gear and align the gear teeth of the idle main gear and sub-gear.

Remove the idle gear and sub-gear.

Remove the idle gear shaft.

Mount the No. 1 idle gear and No. 2 idle sub-gear in a vise.

NOTICE:

Be careful not to damage the gears.

Using SST, turn the No. 1 idle sub-gear clockwise and remove the service bolt.

SST

09960-10010(09962-01000,09963-00600)

Using snap ring pliers, remove the shaft snap ring.

Remove the wave washer, sub-gear and gear spring.

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

NOTICE:

Be careful not to damage the gear.

Using snap ring pliers, remove the shaft snap ring.

Remove the wave washer, sub-gear and gear spring.

Install the idle gear.

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:

0.20 mm (0.0079 in.)

Remove the idle gear.

Using SST, remove the crankshaft timing gear.

SST

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

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:

0.20 mm (0.0079 in.)

Install the supply pump with the 2 nuts.

Torque:

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

Using SST, install the supply pump gear with the nut.

SST

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

Torque:

64 N*m{652 kgf*cm, 47 in.*lbf}

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:

0.20 mm (0.0079 in.)

Install the idle gear without the sub gears.

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:

0.20 mm (0.0079 in.)

Using SST, remove the nut and supply pump gear.

SST

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

Remove the 2 nuts and supply pump.

Remove the idle gear.

Remove the 4 bolts and oil level gauge sensor.

Remove the 22 bolts and 2 nuts.

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.

NOTICE:

1. Do not use a oil pan seal cutter for the timing belt case side 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 union bolt and 8 bolts.

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

Remove the 2 O-rings.

Using a dial indicator, measure the thrust clearance by moving the balance shaft back and forth.

Standard thrust clearance:

0.065 to 0.140 mm (0.0026 to 0.0055 in.)

Maximum thrust clearance:

0.25 mm (0.0098 in.)

HINT:

After replacement, if the thrust clearance is still greater than the maximum, replace the balance shaft.

Remove the 2 bolts and balance shaft.

Mount the balance shaft between aluminum plates in a vise.

NOTICE:

Be careful not to damage the balance shaft.

Remove the bolt, balance shaft driven gear and balance shaft thrust washer.

Using a dial indicator, measure the thrust clearance by moving the balance shaft back and forth.

Standard thrust clearance:

0.065 to 0.140 mm (0.0026 to 0.0055 in.)

Maximum thrust clearance:

0.25 mm (0.0098 in.)

HINT:

After replacement, if the thrust clearance is still greater than the maximum, replace the balance shaft.

Remove the 2 bolts and balance shaft.

Mount the balance shaft between aluminum plates in a vise.

NOTICE:

Be careful not to damage the balance shaft.

Remove the bolt, balance shaft driven gear and balance shaft thrust washer.

Remove the 5 bolts.

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

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.)

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

Remove the 2 connecting rod cap bolts.

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

HINT:

Keep lower bearing inserted to the connecting rod cap.

Clean the crank pin and bearing.

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.

Lay a strip of Plastigage across the crank pin.

Install the connecting rod cap with the 2 bolts.

NOTICE:

Do not turn the crankshaft.

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

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

Measure the Plastigage at its widest point.

Standard oil clearance:

STD	U/S 0.25, U/S 0.50
0.036 to 0.054 mm (0.0014 to 0.0021 in.)	0.037 to 0.077 mm (0.0015 to 0.0030 in.)

Maximum oil clearance:

0.10 mm (0.0039 in.)

HINT:

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, 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.

Bearing size:

Item	Number Mark
Connecting rod cap	1			2			3
Crankshaft	1	2	3	1	2	3	1	2	3
Use bearing	2	3	4	3	4	5	4	5	6

Reference:

Standard connecting rod big end inside diameter:

Mark	Diameter
1	62.014 to 62.020 mm (2.4415 to 2.4417 in.)
2	62.020 to 62.026 mm (2.4417 to 2.4420 in.)
3	62.026 to 62.032 mm (2.4420 to 2.4422 in.)

Standard crank pin diameter:

Mark	Diameter
1	58.994 to 59.000 mm (2.3226 to 2.3228 in.)
2	58.988 to 58.994 mm (2.3224 to 2.3226 in.)
3	58.982 to 58.988 mm (2.3221 to 2.3224 in.)

Standard sized bearing center wall thickness:

Mark	Thickness
1	1.486 to 1.489 mm (0.0585 to 0.0586 in.)
2	1.489 to 1.492 mm (0.0586 to 0.0587 in.)
3	1.492 to 1.495 mm (0.0587 to 0.0589 in.)
4	1.495 to 1.498 mm (0.0589 to 0.0590 in.)
5	1.498 to 1.501 mm (0.0590 to 0.0591 in.)

Completely remove the Plastigage.

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

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

HINT:

1. Keep the bearings, connecting rod and cap together.
   
2. Be sure to organize the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.
   

Check the fit between the piston and piston pin.

1. Try to move the piston back and forth on the piston pin.
   If any movement is felt, replace the piston and pin with a new piston and pin set.
   

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

HINT:

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

Remove the coil and oil ring by hand.

Disconnect the connecting rod from the piston.

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





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





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

   HINT:

   1. The piston and pin are a matched set.
      
   2. 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.
      

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

Standard thrust clearance:

0.040 to 0.240 mm (0.0016 to 0.0094 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

Standard thrust washer thickness:

STD	2.430 to 2.480 mm (0.0957 to 0.0976 in.)
O/S 0.125	2.493 to 2.543 mm (0.0981 to 0.1001 in.)
O/S 0.250	2.680 to 2.730 mm (0.1055 to 0.1074 in.)

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

Using the removed crankshaft bearing cap bolts, move the cap back and forth to remove the crankshaft bearing caps, lower crankshaft bearings and lower thrust washers (No. 3 crankshaft bearing cap only).

HINT:

1. Keep the lower bearing and crankshaft bearing cap together.
   
2. Be sure to organize the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.
   

Lift out the crankshaft.

Clean each main journal and bearing.

Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Install the 5 crankshaft bearing caps with the 10 bolts.

NOTICE:

Do not turn the crankshaft.

Remove the 10 bolts and 5 crankshaft bearing caps.

Measure the Plastigage at its widest point.

Standard oil clearance:

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 clearance:

0.10 mm (0.0039 in.)

HINT:

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

Standard oil clearance:

0.030 to 0.048 mm (0.0012 to 0.0019 in.)

HINT:

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, 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.

Bearing size:

Item	Number Mark
Cylinder block	1			2			3
Crankshaft	1	2	3	1	2	3	1	2	3
Use bearing	2	3	4	3	4	5	4	5	6

HINT:

EXAMPLE: Cylinder block "2" + crankshaft "1"

= Total number 3 (Use bearing "3")

Reference:

Standard cylinder block main journal bore diameter:

Mark	Diameter
1	75.000 to 75.006 mm (2.9528 to 2.9530 in.)
2	75.006 to 75.012 mm (2.9530 to 2.9532 in.)
3	75.012 to 75. 018 mm (2.9532 to 2.9535 in.)

Standard crankshaft journal diameter:

Mark	Diameter
1	69.994 to 70.000 mm (2.7557 to 2.7559 in.)
2	69.988 to 69.994 mm (2.7554 to 2.7557 in.)
3	69.982 to 69.988 mm (2.7552 to 2.7554 in.)

Standard sized bearing center wall thickness:

Mark	Diameter
2	2.482 to 2.485 mm (0.0977 to 0.0978 in.)
3	2.485 to 2.488 mm (0.0978 to 0.0980 in.)
4	2.488 to 2.491 mm (0.0980 to 0.0981 in.)
5	2.491 to 2.494 mm (0.0981 to 0.0982 in.)
6	2.494 to 2.497 mm (0.0982 to 0.0983 in.)

Completely remove the Plastigage.

Lift out the crankshaft.

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

HINT:

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

Remove the 4 check valves and 4 oil nozzles.

Remove the screw plug and gasket.