6.
Disconnect the alternator connector (A) and the cable (B).
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.
Disconnect the battery negative terminal.
Remove the air cleaner assembly.(Refer to Engine and transaxle assembly in this group)
Remove the RH front tire.
Remove the under cover and RH side cover.
Disconnect the engine wiring harness connectors and remove the wiring harness protectors.(Refer to Engine and transaxle assembly in this group)
Disconnect the alternator connector (A) and the cable (B).
Remove the injectors (A), the high pressure pipes (B), the fuel return hose (C) and the turbo charger vacuum hoses (D). (Refer to FL group)
Using the hexagon wrench, turn the tensioner (A) counterclockwise and loosen. Then remove the drive belt (B).
Remove the cylinder head cover (A). Loosen the cylinder head cover bolts in the sequence shown.
Remove the engine mounting support bracket.
Using the engine support fixture (SST No. : 09200-3N000, 09200-38001) hold the engine and adapter.(Refer to MT or AT group)
Remove the engine mounting support bracket (A).
Remove the engine mounting insulator (B).
Remove the oil level gauge guide (A).
Drain the engine oil and then remove the oil filter&cooler assembly (A) after removing the starter. (Refer to Lubrication system in this group)
Remove the alternator (A). (Refer to Alternator in EEB group).
Remove the water pump pulley (A).
Remove the idler (A) and the drive belt tensioner (B).
Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position)
Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
Use the SST(ring gear stopper, 09231-2B100)(A) to remove the crankshaft pulley bolt.
Remove the idler (A) and the timing chain cover plug (B).
Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
Use the SST (ring gear stopper, 09231-2B100) to remove the high pressure pump sprocket nut.
Replace O-ring of plug (B) with a new one when reinstalling the plug.
Disconnect the fuel tubes (A).
Unscrew the three high pressure fuel pump mounting bolts (B, C).
Install the high pressure fuel pump sprocket stopper (A) (SST No.: 09331-2A010) with rotating it clockwise.
Install the high pressure fuel pump remover (SST No.:09331-2A010) (A) with three mounting bolts (B).
Fix the high pressure fuel pump remover (SST No.:09331-2A010) (A) and sprocket stopper (C) with two fixing bolts (D).
Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A010) (A) clockwise till the high pressure fuel pump is pushed out.
Remove the A/C compressor. (Refer to A/C compressor in HA group)
Remove the intercooler pipe (A).
Remove the roll rod bracket (A).
Remove the oil pan (A).
When removing the oil pan, use the SST(09215-3C000) in order not to damage the surface between the bedplate and the oil pan.
Insert the SST between the oil pan and the bedplate 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 the bedplate.
Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
Remove the oil strainer (A).
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 "C" auto tensioner(A).
Before removing auto-tensioner, install a set pin (B) (2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "C" lever (A) and the timing chain guide "1" (B).
Remove the timing chain guide "2" (A).
Remove the timing chain "C" (A).
Remove the timing chain "A" auto tensioner (A).
Before removing auto-tensioner, install a set pin (B) (2.5 mm steel wire) after compressing the tensioner.
Remove timing chain "A" lever (A) and the timing chain guide "1" (B).
Remove the timing chain "A" (A)with high pressure pump sprocket (B) and crankshaft sprocket (C).
Remove the water pump (A).
Take off the hook of the engine support fixture from the front engine hanger.
Set the jack to the bed plate.
Take off the hook of the engine support fixture from the front engine hanger.
Remove the timing chain case (A).
Remove the camshaft sprocket.
Hold the portion (A) of the camshaft with a hexagonal wrench, and remove the bolt (C) with a wrench (B) and remove the camshaft sprocket.
Be careful not to damage the cylinder head and valve lifter with the wrench.
