БЛОК ДВИГАТЕЛЯ РАЗБОРКА

CAUTION / NOTICE / HINT

Note:

  • 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

  1. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    1. Remove the check valve and gasket.

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      *1 No. 2 Nozzle Leakage Pipe
      *a Check Valve

    2. Remove the bolt and No. 2 nozzle leakage pipe.

  2. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    1. Remove the 4 union bolts and 4 gaskets.

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    2. Remove the bolt and No. 1 nozzle leakage pipe.

  3. REMOVE NO. 1 NOZZLE HOLDER CLAMP

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

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  4. REMOVE INJECTOR ASSEMBLY

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  5. REMOVE CAMSHAFT POSITION SENSOR

    1. Remove the bolt and camshaft position sensor.

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  6. REMOVE CRANKSHAFT POSITION SENSOR

    1. Remove the clip and disconnect the crankshaft position sensor harness.

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    2. Remove the 2 bolts and crankshaft position sensor.

  7. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    1. Using SST, remove the engine coolant temperature sensor and gasket.

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      SST
      09817-33190

  8. REMOVE ENGINE WATER PUMP ASSEMBLY

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  9. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  10. REMOVE OIL COOLER ASSEMBLY

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  11. REMOVE NO. 1 OIL COOLER BRACKET

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  12. REMOVE ENGINE OIL LEVEL SENSOR

    1. Remove the 4 bolts and engine oil level sensor.

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  13. REMOVE WATER INLET HOUSING

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  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  15. REMOVE OIL PAN SUB-ASSEMBLY

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  16. REMOVE OIL FILTER ELEMENT

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  17. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

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  18. REMOVE OIL FILTER BRACKET

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  19. REMOVE OIL STRAINER SUB-ASSEMBLY

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  20. REMOVE CRANKSHAFT PULLEY

    1. Set the No. 1 cylinder to TDC/compression.

      1. 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.

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        *a Timing Pointer
        *b Timing Mark

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

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      *a Matchmark
      *b Timing Mark
      Tip:

      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).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tip:

      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.

    4. 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.

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    5. Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt.

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      SST
      09213-58014   ( 91551-80840 )
      09330-00021

    6. Using SST, remove the crankshaft pulley.

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

  21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  22. REMOVE FRONT CRANKSHAFT OIL SEAL

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  23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

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      *a Plunger
      *b Stopper Plate

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )

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

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  24. REMOVE CHAIN TENSIONER SLIPPER

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    1. Remove the chain tensioner slipper from the cylinder block sub-assembly.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. Remove the 2 bolts and No. 1 chain vibration damper.

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  26. REMOVE CAMSHAFT TIMING SPROCKET

    1. Remove the 4 bolts from the camshaft timing sprocket while holding the hexagonal portion of the No. 2 camshaft with a wrench.

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    2. Remove the camshaft timing sprocket and chain sub-assembly.

  27. REMOVE OIL PUMP DRIVE GEAR

    1. Remove the oil pump drive gear from the crankshaft.

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  28. REMOVE CRANKSHAFT TIMING SPROCKET

    1. Remove the crankshaft timing sprocket from the crankshaft.

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  29. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY

    1. Remove the 2 crankshaft pulley set crankshaft keys from the crankshaft.

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  30. REMOVE CAMSHAFT

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  31. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  33. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  34. REMOVE CYLINDER HEAD GASKET

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  35. REMOVE REAR CRANKSHAFT OIL SEAL

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  36. REMOVE NO. 1 OIL PAN BAFFLE PLATE

    1. Remove the 4 bolts and No. 1 oil pan baffle plate.

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  37. REMOVE CYLINDER BLOCK DRAIN COCK PLUG

    1. Remove the cylinder block drain cock plug from the cylinder block sub-assembly.

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