ENGINE UNIT REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354E01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST

      PZ4TB-04941-79

  2. REMOVE ENGINE COVER

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  3. REMOVE ENGINE WIRE

    1. Remove the engine wire from the engine assembly.

  4. REMOVE V-RIBBED BELT

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  5. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

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  6. REMOVE GENERATOR ASSEMBLY

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  7. REMOVE IDLER PULLEY ASSEMBLY

    1. A318391

      Using a T50 "TORX" socket wrench, loosen the bolt to remove the idler pulley assembly.

      Tip:

      The bolt cannot be removed from the idler pulley assembly.

  8. REMOVE ENGINE MOUNTING BRACKET

    1. A318382

      Using an E12 "TORX" socket wrench, remove the 3 bolts and engine mounting bracket.

    2. Remove the 2 stud bolts from the engine mounting bracket.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    1. A318392

      Remove the 2 bolts and V-ribbed belt tensioner assembly.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  12. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

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  13. REMOVE NO. 2 VACUUM HOSE ASSEMBLY

    1. A319683

      Remove the bolt, nut and No. 2 vacuum hose assembly from the No. 2 engine hanger.

  14. REMOVE NO. 1 VACUUM PIPE

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  15. REMOVE INTAKE MANIFOLD

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  16. REMOVE FUEL FEED PIPE SUB-ASSEMBLY

    1. A319681

      Disconnect the nozzle leakage pipe assembly from the fuel feed pipe sub-assembly.

    2. A339096

      Loosen the 2 clamps and disconnect the 2 fuel hoses from the fuel supply pump assembly.

    3. Disconnect the fuel return tube from the common rail assembly.

    4. Detach the fuel hose clamp.

    5. Remove the 2 bolts and fuel feed pipe sub-assembly.

  17. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  19. REMOVE TURBO OIL OUTLET PIPE

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  20. DISCONNECT NO. 1 TURBO OIL PIPE

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  21. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  22. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

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  23. REMOVE EXHAUST MANIFOLD

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  24. REMOVE NO. 1 TURBO OIL PIPE

    1. A339097

      Remove the 2 nuts, union bolt, 2 gaskets and No. 1 turbo oil pipe.

  25. REMOVE NO. 2 TURBO INSULATOR

    1. A339098

      Remove the 3 bolts and No. 2 turbo insulator.

  26. REMOVE TURBOCHARGER STAY

    1. A319845

      Remove the 2 bolts and turbocharger stay.

  27. REMOVE EGR VALVE BRACKET

    1. A347059

      Remove the 2 bolts and EGR valve bracket from the cylinder head sub-assembly.

  28. REMOVE NO. 2 ENGINE HANGER

    1. A339099

      Remove the 2 bolts and No. 2 engine hanger from the cylinder head sub-assembly.

  29. REMOVE NO. 1 ENGINE HANGER

    1. A322238

      Remove the bolt and No. 1 engine hanger from the cylinder head sub-assembly.

  30. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  31. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  32. REMOVE COMMON RAIL ASSEMBLY

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  33. REMOVE GLOW PLUG ASSEMBLY

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  34. REMOVE EGR BYPASS VALVE SWITCHING VALVE

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  35. REMOVE VACUUM CONTROL VALVE BRACKET

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  36. REMOVE DRIVE SHAFT BEARING BRACKET

    1. A347058

      Using a T50 "TORX" socket wrench, remove the 3 bolts and drive shaft bearing bracket.