1.
Disconnect the negative terminal (A) from the battery.
Engine removal is not required for this procedure.
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley, and align its groove with the timing mark of the timing chain cover.
(No.1 cylinder TDC/compression position)
Disconnect the negative terminal (A) from the battery.
Remove the engine cover (A).
Remove the side cover (A).
Using the hexagon wrench, turn the tensioner counterclockwise and loosen. Then remove the drive belt.
Disconnect the engine wire harness connectors and remove the wire harness clamps from the cylinder head cover.
Disconnect the difference pressure sensor connector (A). (With DPF) [Euro - 5 only]
Disconnect the exhaust gas temperature sensor connector (B). (With DPF) [Euro - 5 only]
Disconnect the lambda sensor connector (C). [Euro - 4/5 only]
Disconnect the cam position sensor (CMPS) connector (D).
Disconnect the alternator connector (A) and the cable (B).
Disconnect the starter connector (C) and the cable (D).
Disconnect the air compressor switch connector (E).
Disconnect the injector connectors (A) and remove the injectors, the high pressure pipes (B), the fuel return hose (C) and EGR vacuum hose (D) [Euro - 4/5 only]. (Refer to FL group)
Disconnect the engine ground line (A)
Disconnect the breather hose (A)
Disconnect the brake vacuum hose (A).
Disconnect the power steering oil hoses (A) and remove the power steering pump (B). (Refer to ST group)
Remove the cylinder head cover (A).
Drain the engine oil, and then remove the oil filter&cooler assembly (A).
Drain the engine oil in the oil filter before removing the assembly. (Refer to Lubrication system in this group)
Remove the air compressor (A). (Refer to HA group)
Remove the lower oil pan (A).
Remove the upper oil pan (A).
When removing the upper or lower oil pan, use the SST (09215-3C000) in order not to damage the surface between the cylinder block and the oil pan.
Insert the SST between the oil pan and cylinder block (or upper oil pan) by tapping it with a plastic hammer in the direction of ① arrow.
After tapping the SST with a plastic hammer along the direction of ② arrow around more than 2/3 edge of the oil pan, remove it from cylinder block (or upper oil pan).
Do not turn over the SST abruptly without tapping. It may be result in damage of the SST.
Remove the engine mounting bracket.
Set the jack to the bottom of the cylinder block.
Be careful not to damage the balance shaft & oil pump module.
Remove the engine mounting bracket (A).
Remove the alternator (A).
Remove the fead system bracket assembly (A).
Remove the engine support bracket (A) and the drive belt idler (B).
Set the No.1 cylinder to TDC/compression position.
Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
Do not rotate engine counterclockwise.
Check that the timing mark (A) of the exhaust camshaft timing gear and the timing mark (B) of the intake camshaft timing gear are aligned as shown in the illustration.
If not, turn the crankshaft one revolution (360°). (Do not rotate engine counterclockwise.)
Remove the crankshaft damper pulley (A).
Do not press the pulley or apply the excessive force to prevent the rubber part from being deformed.
Use the SST (ring gear stopper, 09231-2B100) to remove the crankshaft pulley bolt, after remove the starter.
Remove the timing chain cover (A)
Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If any impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.)
Remove the timing chain "B" auto tensioner (A) and guide (B).
Before removing the auto tensioner, install a set pin (C) (ø2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "B" (A) with the camshaft sprocket (B).
Remove the timing chain "A" auto tensioner (A).
Before removing the auto tensioner, install a set pin (B) (ø2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "B" lever (A), the timing chain "A" lever (B) and the timing chain “A” guide (C).
After removing the high pressure pump sprocket nut, install the sprocket stopper (A) of the SST (high pressure pump remover, 09331-1M100).
Rotate the bolt (B) of the SST clockwise till the high pressure pump sprocket is pushed out.
Remove the timing chain "A" (A) with the high pressure pump sprocket (B) and crankshaft sprocket (C).
