Note: This procedure does not require engine removal.
Attention.
- Use protective coatings to prevent damage to painted surfaces.
- Disconnect connectors carefully while holding the connector with your hand to avoid damage.
Note:
- Label all wires and hoses to avoid errors when reconnecting.
- Rotate the crankshaft pulley and align its groove with the alignment mark on the timing chain cover (No. 1 cylinder piston at top dead center on the compression stroke).
1. Disconnect the negative (A) battery wire.
2. Remove the cover (A) engine.
3. Remove the side cover (A).
4. Loosen the tensioner by turning it counterclockwise with a wrench. Then remove the drive belt (A).
5. Disconnect the engine harness connectors and remove the harness clamps from the cylinder head cover.
(1) Disconnect connector (A) differential pressure sensor. (With particulate filter).
(2) Disconnect connector (IN) exhaust gas temperature sensor. (With particulate filter).
(3) Disconnect connector (WITH) oxygen sensor.
(4) Disconnect connector (D) camshaft position sensor (CMPS).
(5) Disconnect connector (A) generator and wire (IN).
(6) Disconnect connector (WITH) starter and wire (D).
(7) Disconnect connector (E) air compressor switch.
6. Disconnect connectors (A) nozzles, remove the nozzles and disconnect the nozzles (IN) high pressure fuel return hose (WITH) and vacuum hose (D) exhaust gas recirculation systems (EGR).
Standard power
Reduced power
7. Disconnect the wire (A) «masses» engine.
8. Disconnect the hose (A) breather.
9. Disconnect the vacuum hose (A).
10. Disconnect the oil hose (A) power steering system and remove the pump (IN) hydraulic booster. (HPS only).
11. Remove the cover (A) cylinder heads.
12. Drain the engine oil, then remove the oil filter and oil cooler assembly (A).
Note: Drain the engine oil from the oil filter before removing.
13. Remove the air compressor (A).
14. Remove the lower oil pan (A).
15. Remove the upper oil pan (A).
Note: In order not to damage the surface between the cylinder block and the oil pan, use the special tool when removing the upper and lower pans (09215-ЗС000).
Attention.
- Install the special tool between the oil pan and the cylinder block (or top oil pan), by lightly tapping it with a plastic mallet in the direction of the arrow.
- While lightly tapping the special tool with a plastic mallet in the direction of the arrow, go along the edge of the oil pan for at least ⅔ of its length. Then remove the pan from the cylinder block (or upper oil pan).
- Do not turn the special tool without tapping. Doing so may damage the special tool.
16. Remove the engine mount bracket.
(1) Install a jack under the cylinder block.
Attention. Be careful not to damage the balance shaft and oil pump module.
(2) Remove bracket (A) engine mounts.
17. Remove the generator (A).
18. Remove bracket (A) complete attachment drive systems.
MDPS type
HPS type
19. Remove the support bracket (A) engine and intermediate roller (IN) drive belt.
20. Set the #1 cylinder piston to top dead center on the compression stroke.
(1) Rotate the crankshaft pulley and align its groove with the alignment mark on the timing chain cover.
Note: Do not turn the crankshaft counterclockwise.
(2) Make sure the installation mark (A) exhaust camshaft gears and alignment mark (IN) the intake camshaft gears are aligned as shown.
Note: Otherwise, turn the crankshaft one turn (360°). (Do not turn the crankshaft counterclockwise).
24. Remove the pulley (A) crankshaft vibration damper.
Attention. Do not press the pulley or apply excessive force to avoid deformation of the rubber part.
Note: Loosen the crankshaft pulley bolt, fixing the ring gear with a special stopper (09231-2B100) (A), then remove the starter.
22. Remove the cover (A) timing chain drive.
Note: After removing the chain cover and oil pan, carefully clean any sealant and oil residue from the sealing surface. (Any contamination of the sealing surface can lead to subsequent oil leakage, despite the application of sealant).
23. Remove auto tensioner (A) chains «IN» timing gear drive and guide (IN).
Note: Before removing the auto tensioner, compress it and insert the dowel pin (WITH) (steel wire ∅ 2.5 mm).
24. Remove the chain (A) «IN» timing gear with sprocket (IN) camshaft.
25. Remove auto tensioner (A) chains «A» timing gear drive.
Note: Before removing the auto tensioner, compress it and insert the dowel pin (IN) (steel wire ∅ 2.5 mm).
26. Remove the lever (A) chains «IN» timing gear drive, lever (IN) chains «A» timing gear drive and guide (WITH) chains «A» timing gear drive.
27. After unscrewing the high pressure pump sprocket nut, install the stopper (A) asterisks (high pressure pump puller 09331-1M100).
28. Rotate the bolt (IN) special tool clockwise until the high pressure pump sprocket is ejected.
29. Remove the chain «A» (A) timing gear drive together with an asterisk (IN) high pressure fuel pump and sprocket (WITH) crankshaft.
