CAUTION / NOTICE / HINT
When replacing the injector assemblies (including exchanging the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.
When replacing the fuel tube sub-assembly, supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
PROCEDURE
REMOVE NO. 2 NOZZLE LEAKAGE PIPE
Remove the check valve and gasket.
*1 | No. 2 Nozzle Leakage Pipe |
*a | Check Valve |
Remove the bolt and No. 2 nozzle leakage pipe.
REMOVE NO. 1 NOZZLE LEAKAGE PIPE
Remove the 4 union bolts and 4 gaskets.
Remove the bolt and No. 1 nozzle leakage pipe.
REMOVE NO. 1 NOZZLE HOLDER CLAMP
Remove the 4 bolts, 4 washers and 4 No. 1 nozzle holder clamps.
REMOVE INJECTOR ASSEMBLY
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REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt and camshaft position sensor.
REMOVE CRANKSHAFT POSITION SENSOR
Remove the clip and disconnect the crankshaft position sensor harness.
Remove the 2 bolts and crankshaft position sensor.
REMOVE ENGINE COOLANT TEMPERATURE SENSOR
Using SST, remove the engine coolant temperature sensor and gasket.
REMOVE ENGINE WATER PUMP ASSEMBLY
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REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY
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REMOVE OIL COOLER ASSEMBLY
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REMOVE NO. 1 OIL COOLER BRACKET
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REMOVE ENGINE OIL LEVEL SENSOR
Remove the 4 bolts and engine oil level sensor.
REMOVE WATER INLET HOUSING
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REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
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REMOVE OIL PAN SUB-ASSEMBLY
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REMOVE OIL FILTER ELEMENT
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REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY
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REMOVE OIL FILTER BRACKET
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REMOVE OIL STRAINER SUB-ASSEMBLY
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REMOVE CRANKSHAFT PULLEY
Set the No. 1 cylinder to TDC/compression.
Turn the crankshaft pulley clockwise to align the timing mark on the crankshaft pulley with the timing pointer on of the timing chain cover sub-assembly.
*a | Timing Pointer |
*b | Timing Mark |
Make sure that the timing mark of the camshaft timing sprocket is at the top.
*a | Matchmark |
*b | Timing Mark |
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 cylinder to TDC/compression).
Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.
The timing chain has 2 pink-colored mark plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.
Turn the crankshaft pulley approximately 90° clockwise from the timing pointer on the timing chain cover sub-assembly so that a lifted valve and piston will not contact each other when removing the camshafts.
Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt.
Using SST, remove the crankshaft pulley.
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
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REMOVE FRONT CRANKSHAFT OIL SEAL
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REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
*a | Plunger |
*b | Stopper Plate |
Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.
Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder block sub-assembly.
REMOVE CHAIN TENSIONER SLIPPER
Remove the chain tensioner slipper from the cylinder block sub-assembly.
REMOVE NO. 1 CHAIN VIBRATION DAMPER
Remove the 2 bolts and No. 1 chain vibration damper.
REMOVE CAMSHAFT TIMING SPROCKET
Remove the 4 bolts from the camshaft timing sprocket while holding the hexagonal portion of the No. 2 camshaft with a wrench.
Remove the camshaft timing sprocket and chain sub-assembly.
REMOVE OIL PUMP DRIVE GEAR
Remove the oil pump drive gear from the crankshaft.
REMOVE CRANKSHAFT TIMING SPROCKET
Remove the crankshaft timing sprocket from the crankshaft.
REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY
Remove the 2 crankshaft pulley set crankshaft keys from the crankshaft.
REMOVE CAMSHAFT
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REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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REMOVE VALVE LASH ADJUSTER ASSEMBLY
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REMOVE CYLINDER HEAD SUB-ASSEMBLY
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REMOVE CYLINDER HEAD GASKET
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REMOVE REAR CRANKSHAFT OIL SEAL
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REMOVE NO. 1 OIL PAN BAFFLE PLATE
Remove the 4 bolts and No. 1 oil pan baffle plate.
REMOVE CYLINDER BLOCK DRAIN COCK PLUG
Remove the cylinder block drain cock plug from the cylinder block sub-assembly.