ENGINE UNIT(w/ DPF) REMOVAL

PROCEDURE


  1. REMOVE ENGINE COVER BRACKET


    1. A01VF14

      Remove the bolt and engine cover bracket from the engine mounting bracket RH.

  2. REMOVE GENERATOR ASSEMBLY


    1. A01VDN1

      Remove the 2 bolts and generator assembly from the engine mounting bracket RH and generator bracket.

  3. REMOVE GENERATOR BRACKET


    1. A01VL8T

      Remove the 2 bolts and generator bracket from the cylinder block sub-assembly.

  4. REMOVE EGR WITH COOLER PIPE ASSEMBLY


    1. A01VJ21

      Disengage the clamp to separate the connector from the EGR with cooler pipe assembly.

    2. A01VIHU

      Disconnect the 3 vacuum transmitting hoses from the EGR with cooler pipe assembly.

    3. Disconnect the vacuum hose from the EGR with cooler pipe assembly.

    4. Slide the hose clip and disconnect the No. 2 oil cooler hose from the EGR with cooler pipe assembly.

    5. Slide the hose clip and disconnect the No. 2 water by-pass hose from the EGR with cooler pipe assembly.

    6. A01VFJI

      Remove the 5 bolts, nut and EGR with cooler pipe assembly from the electric EGR control valve assembly, No. 1 EGR cooler bracket and cylinder head sub-assembly.

    7. A01VIMF

      Remove the EGR pipe gasket from the EGR with cooler pipe assembly.

    8. A01VHQN

      Remove the EGR inlet gasket from the electric EGR control valve assembly.

  5. REMOVE NO. 1 EGR COOLER BRACKET


    1. A01VK8F

      Remove the 2 bolts and No. 1 EGR cooler bracket from the cylinder head sub-assembly.

  6. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)


    1. A01VJ5L

      Disconnect the vacuum hose from the vacuum pump assembly.

    2. Remove the 2 bolts and 2 wiring harness clamp brackets from the cylinder head cover sub-assembly.

  7. REMOVE WIRING HARNESS CLAMP BRACKET (for RHD)


    1. A01VEUX

      Disconnect the vacuum hose from the vacuum pump assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  8. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  9. REMOVE ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY


    1. A01VE7K

      Remove the engine oil level dipstick sub-assembly from the engine oil level dipstick guide sub-assembly.

  10. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A01VK1N

      Remove the bolt and engine oil level dipstick guide sub-assembly from the intake air connector and oil pan sub-assembly.

    2. A01VLWN

      Remove the O-ring from the engine oil level dipstick guide sub-assembly.

  11. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY


    1. A01VEKE

      Disengage the clamp to separate the vacuum transmitting hose assembly from the No. 2 oil cooler hose.

    2. Slide the hose clip and disconnect the No. 3 water by-pass hose from the intake air connector with diesel throttle body assembly.

    3. A01VHAA

      Remove the 2 bolts, 2 nuts and intake air connector with diesel throttle body assembly from the cylinder head sub-assembly.

    4. A01VDOO

      Remove the intake air connector gasket from the cylinder head sub-assembly.

  12. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01VIDJE01
      Text in Illustration
      *1 Lock Bush
      A01VL3H Pull Up

      Slide the hose clip and disconnect the nozzle leakage pipe assembly from the No. 2 nozzle leakage pipe.

    2. Disengage the clamp to separate the nozzle leakage pipe assembly from hose clamp.

    3. Pull up the 4 lock bushes of the nozzle leakage pipe assembly as shown in the illustration, and remove it from each injector assembly.

  13. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. A01VL4H

      Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 1 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the No. 1 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  14. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY


    1. A01VL6X

      Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 2 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the No. 2 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  15. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY


    1. A01VDUU

      Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 3 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the No. 3 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  16. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01VIQ8

      Remove the bolt and No. 2 injection pipe clamp from the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly.

    2. A01VKID

      Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the fuel inlet pipe sub-assembly from the injector assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the fuel inlet pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01VITN

      Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 4 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the No. 4 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  18. REMOVE NO. 2 FUEL HOSE


    1. A01VIVK

      Slide the 2 hose clips and remove the No. 2 fuel hose from the No. 2 nozzle leakage pipe and common rail assembly.

  19. REMOVE NO. 1 FUEL HOSE


    1. A01VHABE02
      Text in Illustration
      *1 Union Bolt
      *2 Gasket

      Slide the hose clip and disconnect the No. 1 fuel hose from the No. 2 nozzle leakage pipe.

    2. Remove the union bolt, No. 1 fuel hose and gasket from the supply pump assembly.

  20. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01VE9Q

      Remove the 2 bolts and No. 2 nozzle leakage pipe from the fuel pump protector and cylinder head cover sub-assembly.

  21. REMOVE FUEL PUMP PROTECTOR


    1. A01VKGM

      Remove the 2 bolts and fuel pump protector from the supply pump assembly.

      Note

      When the fuel pump protector fastening bolt has been loosened, tighten the supply pump assembly fastening bolt to the specified torque Click here.

  22. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01VG0W
      A01VIBZ

      Remove the 3 bolts and supply pump assembly from the cylinder head sub-assembly and No. 3 camshaft bearing cap.

      Note

      If the supply pump drive coupling remains on the camshaft, remove the supply pump drive coupling from the camshaft.

  23. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01VIKN

      Remove the 4 glow plug screw grommets.

    2. A01VDLO

      Remove the 4 nuts and No. 1 glow plug connector from each glow plug assembly.

  24. REMOVE GLOW PLUG ASSEMBLY


    1. A01VHNQ

      Using a deep socket wrench 10 mm, remove the 4 glow plug assemblies from the cylinder head sub-assembly.

  25. REMOVE COMMON RAIL ASSEMBLY


    1. A01VI7L

      Disengage the hose clamp to separate the No. 4 water by-pass hose from the common rail assembly.

    2. Slide the hose clip and remove the No. 4 water by-pass hose from the water inlet pipe.

    3. A01VK70

      Remove the 2 bolts and common rail assembly from the cylinder head sub-assembly.

  26. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

  27. REMOVE NOZZLE HOLDER CLAMP SEAT

    Click here

  28. REMOVE INJECTOR ASSEMBLY

    Click here

  29. REMOVE INJECTION NOZZLE SEAT

    Click here

  30. REMOVE OIL COOLER HOSE


    1. A01VEC0

      Slide the 2 hose clips and remove the oil cooler hose from the water by-pass pipe sub-assembly and oil cooler assembly.

  31. REMOVE NO. 2 OIL COOLER HOSE


    1. A01VJA6

      Disengage the 4 clamps to separate the No. 2 oil cooler hose from the 2 clamps and water by-pass pipe sub-assembly.

    2. Slide the hose clip and remove the No. 2 oil cooler hose from the oil filter bracket sub-assembly.

  32. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A01VF3M

      Slide the hose clip and remove the No. 3 water by-pass hose from the water by-pass pipe sub-assembly.

  33. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A01VM1Z

      Slide the hose clip and remove the No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

  34. REMOVE NO. 1 TURBO WATER HOSE


    1. A01VL4N

      Slide the hose clip and remove the No. 1 turbo water hose from the water by-pass pipe sub-assembly.

  35. REMOVE NO. 2 TURBO WATER HOSE


    1. A01VINQ

      Slide the hose clip and remove the No. 2 turbo water hose from the water by-pass pipe sub-assembly.

  36. REMOVE NO. 6 WATER BY-PASS HOSE


    1. A01VFSS

      Slide the 2 hose clips and remove the No. 6 water by-pass hose from the water by-pass pipe sub-assembly and water outlet sub-assembly.

  37. REMOVE WATER BY-PASS HOSE


    1. A01VLXG

      Slide the hose clip and disconnect the water by-pass hose from the tube connector.

  38. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01VHWV

      Remove the 3 clamps from the water by-pass pipe sub-assembly.

    2. A01VHKT

      Remove the 3 bolts and water by-pass pipe sub-assembly from the No. 2 turbocharger stay, cylinder head sub-assembly, cylinder block sub-assembly and water inlet housing.

    3. A01VIQV

      Slide the hose clip and remove the water by-pass hose from the water by-pass pipe sub-assembly.

    4. A01VK9I

      Remove the water by-pass pipe O-ring from the water by-pass pipe sub-assembly.

  39. REMOVE WATER INLET HOSE RH


    1. A01VJWK

      Slide the 2 hose clips and remove the water inlet hose RH from the water outlet sub-assembly and water inlet pipe.

  40. REMOVE WATER INLET HOSE LH


    1. A01VGOE

      Slide the 2 hose clips and remove the water inlet hose LH from the water inlet pipe and water inlet housing.

  41. REMOVE WATER INLET PIPE


    1. A01VH3Q

      Remove the 2 bolts and water inlet pipe from the cylinder block sub-assembly.

  42. REMOVE VACUUM PUMP ASSEMBLY


    1. A01VM8K

      Remove the 2 bolts and vacuum pump assembly from the cylinder head sub-assembly.

    2. A01VJMG

      Remove the 2 O-rings from the vacuum pump assembly.

  43. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01VEDN

      Remove the 2 bolts and V-ribbed belt tensioner assembly from the timing chain cover assembly.

  44. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01VM06

      Remove the bolt and wiring harness clamp bracket from the timing chain cover assembly.

  45. REMOVE NO. 2 TURBOCHARGER STAY


    1. A01VLZY

      Remove the 2 bolts and No. 2 turbocharger stay from the cylinder head sub-assembly.

  46. REMOVE OIL PAN COVER


    1. A01VH75

      Remove the 2 bolts, 2 plate washers and oil pan cover from the oil pan sub-assembly.

  47. REMOVE NO. 2 OIL PAN COVER SILENCER


    1. A01VKCK

      Remove the 2 bolts, 2 plate washers and No. 2 oil pan cover silencer from the oil pan sub-assembly.