GSIC - Global Service Information Center

# ENGINE UNIT > DISASSEMBLY

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1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

2. REMOVE NOZZLE HOLDER SEAL

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

3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

1. Uniformly loosen and remove the 18 cylinder head bolts in several passes in the sequence shown in the illustration.

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

1. 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.

4. REMOVE INJECTOR ASSEMBLY

1. 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.

1. 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.

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

1. Remove the 4 injection nozzle sheets from the cylinder head.

5. REMOVE CAMSHAFT TIMING PULLEY

1. 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.

1. Remove the camshaft timing pulley.

6. REMOVE NO. 2 TIMING BELT COVER

1. Remove the 4 bolts, nuts and timing belt cover.

7. REMOVE CAMSHAFT

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

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

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

8. REMOVE CYLINDER HEAD SUB-ASSEMBLY

1. Uniformly loosen and remove the 18 cylinder head bolts in several passes in the sequence shown in the illustration.

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

1. 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.

9. REMOVE WATER PUMP ASSEMBLY

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

10. REMOVE TIMING GEAR CASE

1. Remove the 14 bolts and 2 nuts.

1. Pry the gear cover in the location shown in the illustration, and remove the gear cover together with the supply pump drive gear.

   NOTICE:
     Be careful not to drop the supply pump gear.

1. Remove the O-ring from the timing belt cover.

11. REMOVE SUPPLY PUMP GEAR

1. Using SST, remove the injection gear.

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

12. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR

1. Remove the bolt, sensor and O-ring.

13. REMOVE NO. 1 IDLE GEAR

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

1. Remove the 2 bolts and thrust plate.

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

1. Remove the idle gear and sub-gear.

1. Remove the idle gear shaft.

14. REMOVE NO. 1 IDLE SUB GEAR

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

   NOTICE:
     Be careful not to damage the gears.

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

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

1. Using snap ring pliers, remove the shaft snap ring.

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

15. REMOVE NO. 2 IDLE SUB GEAR

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

   NOTICE:
     Be careful not a damage the gear.

1. Using snap ring pliers, remove the shaft snap ring.

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

16. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

1. Using SST, remove the crankshaft timing gear.

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

17. REMOVE OIL PAN SUB-ASSEMBLY

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

1. Remove the 22 bolts and 2 nuts.

1. Insert the blade of SST between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

   SST
     09032-00100

   NOTICE:
   1. Do not use SST for the timing belt case side and rear oil seal retainer.
   2. Be careful not to damage the oil pan flange.

18. REMOVE OIL STRAINER SUB-ASSEMBLY

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

19. REMOVE TIMING GEAR CASE ASSEMBLY

1. Remove the union bolt and 8 bolts.

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

1. Remove the 2 O-rings.

20. REMOVE NO. 1 BALANCE SHAFT SUB-ASSEMBLY

1. Remove the 2 bolts and balance shaft.

21. REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR

1. Mount the balance shaft between aluminium plates in a vise.

   NOTICE:
     Be careful not to damage the balance shaft.

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

22. REMOVE NO. 2 BALANCE SHAFT SUB-ASSEMBLY

1. Remove the 2 bolts and balance shaft.

23. REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR

1. Mount the balance shaft between aluminium plates in a vise.

   NOTICE:
     Be careful not to damage the balance shaft.

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

24. REMOVE ENGINE REAR OIL SEAL RETAINER

1. Remove the 5 bolts.

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

25. REMOVE SUPPLY PUMP GEAR BEARING

1. Using SST, remove the bearing.

   SST
     09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
     09950-60010 (09951-00390, 09951-00460, 09952-06010)

26. REMOVE CYLINDER BLOCK OIL ORIFICE

27. REMOVE PISTON AND CONNECTING ROD

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

1. Remove the 2 connecting road cap bolts.

1. Using the 2 removed connecting rod bolts, pry the connecting rod cap back and forth, and remove the connecting cap.

   HINT:
     Keep the lower bearing inserted with the connecting rod cap.

1. Clean the crank pin and bearing.

1. 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.

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

1. 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.

28. REMOVE PISTON PIN

1. Check 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 a set.

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

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

1. Remove the 2 side rails and oil ring by hand.

1. 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 and 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.

29. REMOVE CRANKSHAFT SUB-ASSEMBLY

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

1. Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and 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 bearings 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.

1. Lift out the crankshaft.

1. 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.

30. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

1. Remove the 4 check valves and oil nozzles.

31. REMOVE NO. 1 WITH HEAD STRAIGHT SCREW PLUG

1. Remove the screw plug and gasket.