ENGINE ASSEMBLY REMOVAL


  1. REMOVE ENGINE UNDER COVER

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. Remove the drain plug from the oil pan and drain engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E01

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  5. DRAIN POWER STEERING FLUID

  6. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH

  7. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH

  8. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. A01CGLT

      Remove the bolt and 3 nuts.

    2. Remove the radiator reserve tank assembly.

  9. REMOVE FENDER SIDE APRON SUB-ASSEMBLY LH

  10. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH

  11. REMOVE VACUUM RESERVOIR SUB-ASSEMBLY

  12. REMOVE SPILL VALVE CONTROL DRIVER ASSEMBLY


    1. A01CHRZ

      Disconnect the 2 injector driver connectors.

    2. A01CHZZE01

      Remove the 2 bolts and remove the injector driver.

  13. REMOVE NO. 2 INTAKE PIPE


    1. A01CHUN

      Remove the 3 bolts, loosen the 2 bands, and remove the No. 2 intake pipe.

  14. REMOVE NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. A01CH0N

      Disconnect the connector. (with Cab tilt warning)

    2. A01CJGK

      Remove the 4 nuts and remove the air cleaner case.

    3. A01CIIG

      Remove the 2 bolts and remove the No. 1 air hose assembly.

    4. A01CIY0

      Remove the 8 bolts and remove the No. 3 cab mounting bracket.

  15. REMOVE NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CIMYE01

      Disconnect the hose band.

    2. A01CGQKE01

      Remove the 2 bolts and bracket.

    3. A01CHLBE01

      Disconnect the turbo pressure sensor connector and wire harness clamp, and remove the bolt.

    4. A01CHYE

      Disconnect the intake air temperature sensor connector, and remove the bolt.

    5. A01CILLE01

      Disconnect the hose band, and remove the No. 1 intake air pipe with No. 4 air hose.

  16. REMOVE NO. 2 AIR HOSE


    1. A01CITQE01

      Disconnect the 2 hose bands and No. 1 air hose.

  17. REMOVE INTERCOOLER ASSEMBLY


    1. A01CIBUE01

      Remove the 4 bolts and intercooler assembly.

  18. REMOVE FAN


    1. Remove the 4 nuts.

    2. Remove the fan and generator V belt.

      Tech Tips

      Click here

    3. Remove the 4 nuts and remove the pulley and fan.

  19. REMOVE FAN PULLEY


    1. A01CI13

      Remove the fan pulley.

  20. DISCONNECT RADIATOR HOSE INLET


    1. Disconnect the radiator hose inlet.

  21. DISCONNECT RADIATOR HOSE OUTLET


    1. Remove the radiator hose outlet.

  22. SEPARATE HEATER HOSE


    1. A01CJFI

      Remove the 5 bolts and separate the heater hose.

  23. SEPARATE NO. 4 RADIATOR BRACKET


    1. A01CJBO

      Remove the 3 bolts and separate the No. 4 radiator bracket.

    2. Remove the bolt and radiator support No. 2.

  24. SEPARATE NO. 3 RADIATOR BRACKET


    1. A01CIT5

      Remove the 3 bolts and separate the No. 3 radiator bracket.

    2. Remove the bolt and No. 1 radiator support.

  25. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly with fan shroud.

  26. REMOVE GENERATOR ASSEMBLY


    1. A01CI5J

      Remove the terminal cap and the nut, disconnect the wire harness from terminal B.

    2. Disconnect the connector from the generator.

    3. Disconnect the 3 wire harness clamps.

    4. A01CGO2

      Remove the 4 bolts, generator bracket and generator assembly.

  27. REMOVE STARTER ASSEMBLY


    1. A01CICI

      Disconnect the 2 wire harness clamps.

    2. Remove the bolt and the wire harness clamp bracket.

    3. Pull off the terminal cap and remove the bolt, and disconnect the starter wire from terminal B.

    4. Pull off the terminal cap and remove the nut, and disconnect the starter wire from terminal C.

    5. A01CGQR

      Remove the nut, bolt and the starter assembly.

  28. DISCONNECT HEATER HOSE

  29. REMOVE EXHAUST RETARDER ASSEMBLY


    1. A01CIBFE01

      Disconnect the vacuum hose.

    2. A01CHNOE01

      Remove the 4 bolts and exhaust retarder assembly.

    3. Remove the 2 gaskets.

  30. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01CHG1E01

      Remove the bolt.

    2. A01CI20E01

      Remove the 3 nuts and front exhaust pipe assembly.

    3. Remove the gasket.

  31. DISCONNECT PROPELLER SHAFT ASSEMBLY

  32. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01CHMO

      Remove the 2 bolts and disconnect the clutch release cylinder.

  33. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. A01CHK5E01

      Remove the nut and control select cable from the select lever.

  34. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. A01CIE5E01

      Remove the nut and control shift cable from the shift lever.

  35. DISCONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE


    1. A01CHED

      Disconnect the No. 2 oil reservoir to pump hose.

  36. REMOVE PRESSURE FEED HOSE


    1. A01CH96

      Using SST, separate the pressure feed hose.

      SST
      09023-12901

    2. Remove the gasket from the pressure feed hose.

  37. DISCONNECT FUEL HOSE


    1. A01CIXU

      Disconnect the 2 fuel hoses.

  38. DISCONNECT WIRE HARNESS


    1. Disconnect the wire harness.

  39. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. A01CH0V

      Using a chisel and a hammer, release the staked part of the transmission output shaft rear set nut.

    2. Pull the parking brake lever fully, and shift into the reverse position.

    3. A01CHRW

      Using a 36 mm socket wrench, remove the transmission output shaft rear set nut.

    4. Using a screwdriver, remove the O-ring.

  40. REMOVE PARKING BRAKE DRUM SUB-ASSEMBLY


    1. A01CID4

      Remove the bolt and dust cover from the parking brake drum.

    2. Release the parking brake lever.

    3. Remove the parking brake drum sub-assembly and companion flange.

    4. A01CJER

      If the brake drum cannot be removed easily, turn the shoe adjuster in the direction of the illustrated arrow mark until the drum turns freely.

  41. SEPARATE PARKING BRAKE PLATE SUB-ASSEMBLY


    1. A01CI7A

      Remove the 4 nuts and disconnect the parking brake plate sub-assembly.

      Tech Tips

      Use wire or an equivalent tool to keep the parking brake plate sub-assembly from hanging down by the parking brake cable.

  42. SUPPORT TRANSMISSION ASSEMBLY


    1. Support the transmission assembly with a transmission jack.

  43. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET


    1. A01CH6D

      Remove the nut.

    2. A01CI1C

      Remove the 3 bolts and 3 washers and disconnect the No. 3 engine mounting bracket.

  44. DISCONNECT NO. 1 ENGINE MOUNTING BRACKET


    1. A01CH1X

      Remove the nut.

    2. A01CI3C

      Remove the 3 bolts and 3 washers and disconnect the No. 1 engine mounting bracket.

  45. SUPPORT ENGINE ASSEMBLY


    1. A01CISZ

      Install the engine hanger with the 2 bolts.

      Torque:
      108 N*m  { 1100 kgf*cm, 80 ft.*lbf }
    2. A01CGMU

      Attach the sling device and the engine with the chain block.

  46. REMOVE MANUAL TRANSMISSION ASSEMBLY


    1. Disconnect the connector and clamp.

    2. A01CHNG

      Remove the 12 bolts.

    3. Remove the transmission assembly.

      Note

      Do not apply excessive force to the transmission assembly as this will cause the input shaft to break.

  47. REMOVE CLUTCH COVER ASSEMBLY


    1. A01CI2IE01

      Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the set bolts, and pull off the clutch cover assembly.

      Note

      Do not drop the clutch disc assembly.

  48. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc assembly, the pressure plate and the surface of the flywheel sub-assembly away from oil and foreign matter.

  49. REMOVE ENGINE ASSEMBLY


    1. Remove the 2 nuts and engine from the engine mounting brackets.

    2. Remove the engine hanger.

  50. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Separate the water by-pass hose.

    2. Remove the 6 bolts and remove the EGR cooler.

  51. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Remove the oil filler cap sub-assembly.

  52. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

      Remove the 2 bolts and remove the No. 2 cylinder head cover sub-assembly.

  53. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CGZM

      Remove the wire harness.

    2. Remove the cylinder head cover cushion rubber.

    3. Remove the 2 bolts and remove the cylinder head cover sub-assembly.

  54. REMOVE DIESEL THROTTLE BODY


    1. A01CIXR

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH6X

      Remove the 2 bolts, 2 nuts and diesel throttle body.

  55. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CH2B

      Disconnect the 3 connectors.

  56. REMOVE VENTILATION PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts.

    2. Disconnect the 3 hoses and remove the ventilation pipe sub-assembly.

  57. REMOVE EGR VALVE BRACKET


    1. A01CIJH

      Remove the 4 bolts and bracket.

  58. REMOVE OIL SEPARATOR ASSEMBLY


    1. A01CGWZ

      Move the clamp and disconnect the hose.

    2. Remove the 2 bolts and the oil separator assembly.

  59. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CI5V

      Remove the 3 bolts and 2 union bolts.

    2. Remove the water by-pass pipe.

  60. REMOVE VENTURI ASSEMBLY


    1. Remove the 4 bolts, 2 nuts and venturi from the intake manifold.

  61. REMOVE INJECTION PIPE CLAMP


    1. A01CHFZ

      Remove the 2 nuts, oil level dipstick guide and the 2 pipe clamps.

  62. REMOVE OIL LEVEL GAUGE GUIDE


    1. Remove the oil level gauge guide.

  63. REMOVE INJECTOR ASSEMBLY


    1. A01CGVZ

      Remove the union bolt, the 4 hollow screws, the 5 gaskets and the nozzle leakage pipe.

      Note

      After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector.

    2. A01CIVME01

      Using a small screwdriver, move the 4 holder seals.

    3. A01CGOO

      Remove the 4 bolts and the 4 nozzle holder clamps.

      Note

      Arrange the holder clamps and bolts in the correct order.

    4. Remove the 4 injectors.

      Note

      Arrange the injectors in the correct order.

    5. Remove the No. 2 cylinder head cover gasket from each injector.

    6. A01CI6EE01

      Remove the O-ring from each injector.

    7. Remove the 4 injection nozzle seats from the cylinder head.

  64. REMOVE VANE PUMP ASSEMBLY


    1. A01CHBBE03

      Remove the 2 bolts and remove the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  65. REMOVE GENERATOR BELT ADJUSTING BAR


    1. Remove the 2 bolts and remove the generator belt adjusting bar.

  66. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. A01CHR0

      Remove the 3 bolts and remove the generator bracket.

  67. REMOVE RADIATOR PIPE


    1. A01CIP1

      Remove the 2 bolts and remove the radiator pipe.

  68. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here

  69. REMOVE EXHAUST MANIFOLD


    1. A01CHWE

      Remove the 3 bolts and remove the exhaust manifold heat insulator sub-assembly.

    2. A01CJ2L

      Remove the 8 nuts and remove the exhaust manifold.

  70. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01CJCF

      Remove the engine oil pressure switch assembly.

  71. REMOVE OIL COOLER ASSEMBLY


    1. A01CGSY

      Remove the 15 bolts and oil cooler assembly with bracket.

    2. A01CH3V

      Remove the 4 nuts and oil cooler assembly.

    3. Remove the 2 gaskets.

  72. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Remove the bolt and remove the crankshaft position sensor.

  73. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Remove the bolt and remove the camshaft position sensor.

  74. REMOVE WATER OUTLET SUB-ASSEMBLY

    A01CITH

    Remove the 3 bolts and remove the water outlet sub-assembly.

  75. REMOVE THERMOSTAT


    1. A01CGN5

      Remove the 3 bolts and water outlet.

    2. Remove the thermostat from the cylinder block.

    3. Remove the gasket from the thermostat.

  76. REMOVE WATER TEMPERATURE SENDER GAUGE ASSEMBLY


    1. A01CJ4L

      Disconnect the connector.

    2. Remove the water temperature sender gauge assembly.

  77. REMOVE WATER OUTLET HOUSING


    1. A01CHN1

      Remove the 3 bolts and remove the water outlet housing.

  78. REMOVE WATER PIPE SUB-ASSEMBLY


    1. A01CIX4

      Remove the 3 bolts and remove the water pipe sub-assembly.

  79. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Remove the 7 bolts and remove the water by-pass pipe sub-assembly.

  80. REMOVE WATER PUMP ASSEMBLY


    1. A01CIV9

      Remove the 8 bolts and water pump assembly.

  81. REMOVE VACUUM PIPE


    1. Remove the union bolt and bolt and remove the vacuum pipe.

  82. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

      Remove the 3 bolts and remove the vacuum pump oil pipe sub-assembly.

  83. REMOVE VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Remove the 2 nuts and remove the vacuum pump assembly.

  84. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01CJ4U

      Remove the 2 union bolts, the 4 gaskets and the No. 4 fuel pipe sub-assembly.

  85. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJ7V

      Remove the nut and the fuel pipe clamp.

    2. Using SST, loosen the union nuts and remove the fuel filter to injection pump fuel pipe.

      SST
      09023-12901

  86. REMOVE COMMON RAIL ASSEMBLY


    1. A01CIBY

      Disconnect the fuel pressure sensor connector.

    2. Remove the 2 bolts, the No. 3 injection pipe bracket and the common rail assembly.

  87. REMOVE FUEL DELIVERY PIPE


    1. A01CICS

      Remove the union bolt, the 2 gaskets and the fuel delivery pipe.

  88. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CIXS

      Remove the nut and the fuel pipe clamp.

    2. Remove the union bolt, the gasket and the fuel return pipe sub-assembly.

  89. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01CIH3

      Disconnect the 2 connectors.

    2. Remove the bolt and the holder clip.

    3. A01CGZX

      Remove the 4 bolts and the injection or supply pump assembly.

    4. Remove the O-ring from the timer cover.

  90. REMOVE INTAKE MANIFOLD


    1. A01CIOK

      Remove the 8 bolts and 2 nuts and remove the intake manifold.