Engine Unit Disassembly

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

Remove the 10 bolts, 2 nuts, cylinder head cover and 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 nozzle leakage 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 the timing belt is not installed when removing the bolt of camshaft timing pulley.

Remove the camshaft timing pulley.

Remove the 4 bolts, nuts and No. 2 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.

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

HINT:

If the cylinder head is difficult to remove, 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 at the locations shown in the illustration, and remove the gear cover together with the injection gear.

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 SST, remove the crankshaft timing gear.

SST

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

Remove the 2 bolts and thrust plate.

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

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, No. 1 idle sub gear and idle gear spring.

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

NOTICE:

Be careful not a damage the gear.

Using snap ring pliers, remove the shaft snap ring.

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

Remove the idle gear shaft.

Remove the 11 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

Remove the 2 nuts, oil strainer and gasket.

Remove the 22 bolts and 2 nuts.

Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the gasket.

Remove the union bolt and 8 bolts.

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

Remove the 2 O-rings.

Using a dial indicator, measure the thrust clearance while moving the No. 1 balanceshaft back and forth.

Standard thrust clearance:

0.065 to 0.140 mm (0.00256 to 0.00551 in.)

Maximum thrust clearance:

0.25 mm (0.00984 in.)

Remove the 2 bolts and balanceshaft.

Mount the balanceshaft between aluminum plates in a vise.

NOTICE:

Be careful not to damage the balanceshaft.

Remove the bolt, balanceshaft driven gear and balanceshaft thrust washer.

Using a dial indicator, measure the thrust clearance while moving the No. 2 balanceshaft back and forth.

Standard thrust clearance:

0.065 to 0.140 mm (0.00256 to 0.00551 in.)

Maximum thrust clearance:

0.25 mm (0.00984 in.)

Remove the 2 bolts and balanceshaft.

Mount the balanceshaft between aluminum plates in a vise.

NOTICE:

Be careful not to damage the balanceshaft.

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

Remove the 5 bolts.

Using a screwdriver, remove the oil seal retainer by prying between the 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.