ENGINE UNIT > DISASSEMBLY

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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.
   

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.
   

2. Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.
   

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.
      

2. 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.

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

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

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.

2. Remove the camshaft timing pulley.
   

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

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

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

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

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.

2. 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.

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

1. Remove the 14 bolts and 2 nuts.
   

2. 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.

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

1. Using SST, remove the injection gear.
   

   SST

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

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

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

2. Remove the 2 bolts and thrust plate.
   

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

4. Remove the idle gear and sub-ear.
   

5. Remove the idle gear shaft.
   

1. Using SST, align the holes of the idler main gear and sub gears by turning the sub-ear clockwise, and install a service bolt.
   

   SST

   09960-10010   (09962-01000, 09963-00700)
   

2. Using snap ring pliers, remove the snap ring.
   

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

1. Using SST, remove the crankshaft timing gear.
   

   SST

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

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

2. Remove the 22 bolts and 2 nuts.
   

3. 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.
      

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

1. Remove the union bolt and 8 bolts.
   

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

3. Remove the 2 O-rings.
   

1. Remove the 5 bolts.
   

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

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)
   

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

2. Remove the 2 connecting road cap bolts.
   

3. 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.

4. Clean the crank pin and bearing.
   

5. 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.
   

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

7. Push 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.
      

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.
      

2. 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.

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

4. Disconnect the connecting rod from the piston.
   
   

   1. Using a small screwdriver, pry off the 2 snaps ring 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.
         

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

2. 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.
      

3. Lift out the crankshaft.
   

4. 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.

1. Remove the 4 check valves and oil nozzles.
   

1. Remove the screw plug and gasket.