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 and gasket 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 loosen the radiator drain cock plug and engine drain plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E02
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap sub-assembly, 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 INJECTOR DRIVER ASSEMBLY


    1. Disconnect the 2 injector driver connectors.

    2. A01CHLQ

      Disconnect the wire harness clamp and connector from the injector driver assembly.

    3. Remove the 2 bolts and injector driver assembly.

  13. REMOVE NO. 2 INTAKE PIPE


    1. A01CHOY

      Remove the 3 bolts, loosen the 2 hose bands, and remove the No. 2 intake pipe and No. 1 air hose.

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


    1. A01CH0N

      Disconnect the connector (w/ Cab tilt warning).

    2. A01CJGK

      Remove the 4 nuts and air cleaner case.

    3. A01CIIG

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

    4. A01CIY0

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

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


    1. A01CJ0J

      Disconnect the hose band.

    2. A01CGN2

      Remove the bolt.

    3. A01CJ8T

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

    4. A01CJ3X

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

  16. REMOVE NO. 2 AIR HOSE


    1. A01CJB7

      Loosen the 2 hose bands and remove the No. 2 air hose.

  17. REMOVE INTERCOOLER ASSEMBLY


    1. A01CISR

      Remove the 4 bolts and intercooler assembly.

  18. REMOVE FAN


    1. Loosen the 4 nuts.

    2. Remove the fan and generator V belt Click here.

    3. Remove the 4 nuts and fan.

  19. REMOVE NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)


    1. A01CHHDE01

      Loosen the bolt (A).

    2. Loosen the bolt (B), then remove the No. 1 V (cooler compressor to crankshaft pulley) belt.

  20. REMOVE FAN PULLEY


    1. A01CI13

      Remove the fan pulley.

  21. DISCONNECT INLET RADIATOR HOSE


    1. Disconnect the inlet radiator hose.

  22. DISCONNECT OUTLET RADIATOR HOSE


    1. Disconnect the outlet radiator hose.

  23. DISCONNECT HEATER HOSE


    1. A01CJFI

      Remove the 5 bolts and separate the heater hose.

  24. SEPARATE NO. 4 RADIATOR BRACKET


    1. A01CIT5

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

  25. SEPARATE NO. 3 RADIATOR BRACKET


    1. A01CJBO

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

  26. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly with the fan shroud.

  27. REMOVE GENERATOR ASSEMBLY


    1. A01CI5J

      Remove the terminal cap and nut, and 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 belt adjusting bar and generator assembly.

  28. 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, remove the nut and disconnect the starter wire from terminal B.

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

    5. A01CGQR

      Remove the nut, bolt and starter assembly.

  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 from the exhaust retarder assembly.

  30. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01CHG1

      Remove the bolt.

    2. A01CI20E01

      Remove the 3 nuts and front exhaust pipe assembly.

    3. Remove the gasket.

  31. REMOVE PROPELLER SHAFT ASSEMBLY

  32. REMOVE PROPELLER INTERMEDIATE SHAFT ASSEMBLY

  33. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

  34. DISCONNECT TRANSMISSION CONTROL SELECT CABLE

  35. DISCONNECT TRANSMISSION CONTROL SHIFT CABLE

  36. DISCONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE


    1. A01CHED

      Disconnect the No. 2 oil reservoir to pump hose.

  37. REMOVE PRESSURE FEED HOSE


    1. A01CH96

      Using a union nut wrench (19 mm), separate the pressure feed hose.

    2. Remove the gasket from the pressure feed hose.

  38. DISCONNECT FUEL HOSE


    1. A01CIXU

      Disconnect the 2 fuel hoses.

  39. DISCONNECT WIRE HARNESS


    1. Disconnect the wire harness.

  40. REMOVE REAR MANUAL TRANSMISSION OUTPUT SHAFT SET NUT

  41. REMOVE PARKING BRAKE DRUM SUB-ASSEMBLY

  42. SEPARATE PARKING BRAKE PLATE SUB-ASSEMBLY

  43. SUPPORT TRANSMISSION ASSEMBLY

  44. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET

  45. DISCONNECT NO. 1 ENGINE MOUNTING BRACKET

  46. SUPPORT ENGINE ASSEMBLY


    1. A01CISZ

      Install the engine hanger with the 2 bolts.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }
    2. A01CGMU

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

  47. REMOVE MANUAL TRANSMISSION ASSEMBLY

  48. REMOVE CLUTCH COVER ASSEMBLY

  49. REMOVE CLUTCH DISC ASSEMBLY

  50. REMOVE ENGINE ASSEMBLY


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

    2. Remove the engine hanger.

  51. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Disconnect the water by-pass hose.

    2. Remove the 6 bolts, EGR cooler sub-assembly, bracket and 2 gaskets.

  52. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Remove the oil filler cap sub-assembly.

  53. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

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

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


    1. A01CGZM

      Remove the wire harness.

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

    3. Remove the cushions, spacers and gasket.

  55. REMOVE DIESEL THROTTLE BODY


    1. A01CHFJ

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH93

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

  56. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CIEE

      Disconnect the 3 connectors, 4 wire harness clamps and bolt.

  57. REMOVE EGR VALVE BRACKET


    1. A01CGLD

      Remove the 4 bolts and bracket.

  58. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CHT5

      Remove the 3 bolts and 2 union bolts.

    2. Remove the water by-pass pipe and gasket.

  59. REMOVE VENTURI ASSEMBLY


    1. Remove the bolt and bracket from the venturi assembly.

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

  60. REMOVE INJECTION PIPE CLAMP


    1. A01CGTY

      Remove the 2 nuts.

    2. Remove the oil level gauge.

    3. Remove the oil level gauge guide and O-ring, and then remove the 2 injection pipe clamps.

  61. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick guide and O-ring.

  62. REMOVE INJECTOR ASSEMBLY


    1. A01CHN3

      Using a union nut wrench (17 mm), loosen the 8 union nuts and remove the injection pipe sub-assembly.

    2. A01CGVZ

      Remove the 5 hollow screws and 5 gaskets, and then remove the nozzle leakage pipe.

      Tech Tips

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

    3. A01CIVM

      Using a small screwdriver, remove the 4 holder seals.

    4. A01CGOO

      Remove the 4 bolts and the 4 nozzle holder clamps.

      Note

      Arrange the holder clamps and bolts in the correct order.

    5. Remove the 4 injectors.

      Note

      Arrange the injectors in the correct order.

    6. Attach tags to identify the cylinder (#1 to #4) to the injector assemblies so that each injector assembly can be inserted into the correct cylinder during installation.

    7. Remove the gasket from each injector.

    8. A01CI6EE02
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each injector.

  63. REMOVE VANE PUMP ASSEMBLY


    1. A01CHBBE03

      Remove the 2 bolts and vane pump assembly.

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

  64. REMOVE GENERATOR BELT ADJUSTING BAR


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

  65. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. A01CHR0

      Disconnect the connector clamp.

    2. Remove the 3 bolts and generator bracket.

  66. REMOVE RADIATOR PIPE


    1. A01CIP1

      Remove the 2 bolts, radiator pipe and O-ring.

  67. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here.

  68. REMOVE EXHAUST MANIFOLD


    1. A01CHWE

      Remove the 3 bolts and exhaust manifold heat insulator.

    2. A01CJ2L

      Remove the 8 nuts and exhaust manifold.

  69. REMOVE GLOW PLUG GROUND WIRE


    1. Remove the 4 screw grommets.

    2. Remove the 4 nuts.

    3. Remove the wire harness and 3 glow plug ground wires.

  70. REMOVE GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, remove the 4 glow plugs.

  71. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01CJCF

      Remove the engine oil pressure switch assembly and O-ring.

  72. REMOVE OIL COOLER ASSEMBLY


    1. A01CJFB

      Remove the 2 bolts and wire harness bracket.

    2. A01CJ6BE01

      Remove the 15 bolts and oil cooler assembly with the bracket.

    3. A01CH3V

      Remove the 4 nuts and oil cooler assembly.

    4. Remove the 2 gaskets.

  73. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Remove the bolt and crankshaft position sensor.

    2. Remove the O-ring from the crankshaft position sensor.

  74. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Remove the bolt and camshaft position sensor.

    2. Remove the O-ring from the camshaft position sensor.

  75. REMOVE WATER OUTLET SUB-ASSEMBLY

    A01CGNU

    Remove the 3 bolts and water outlet sub-assembly.

  76. REMOVE THERMOSTAT


    1. A01CGNU

      Remove the 3 bolts and water outlet.

    2. Remove the thermostat from the cylinder block.

    3. Remove the gasket from the thermostat.

  77. REMOVE WATER TEMPERATURE SENDER GAUGE ASSEMBLY


    1. A01CJ4L

      Disconnect the connector.

    2. Remove the water temperature sender gauge assembly and gasket.

  78. REMOVE WATER OUTLET HOUSING


    1. A01CHN1

      Remove the 3 bolts and water outlet housing.

  79. REMOVE WATER PIPE SUB-ASSEMBLY


    1. A01CIX4

      Remove the 3 bolts, clamp and water pipe sub-assembly.

    2. Remove the O-ring.

  80. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Remove the 6 bolts and water by-pass pipe sub-assembly.

    2. Remove the 2 O-rings.

  81. REMOVE WATER PUMP ASSEMBLY


    1. A01CIV9

      Remove the 8 bolts and water pump assembly.

  82. REMOVE VACUUM PIPE


    1. Remove the union bolt, bolt, 2 gaskets and vacuum pipe.

  83. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

      Remove the 3 union bolts, gaskets and vacuum pump oil pipe sub-assembly.

  84. REMOVE VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Remove the 2 nuts and vacuum pump assembly.

  85. REMOVE FUEL PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts and nut, and then remove the 3 fuel pipe clamps.

    2. Remove the union bolt and gaskets, and then remove the fuel pipe sub-assembly.

  86. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. Disconnect the wire harness connector.

    2. A01CHXB

      Disconnect the 2 wire harness clamps.

    3. A01CJB8

      Remove the nut and fuel pipe clamp.

    4. Using a union nut wrench (17 mm), loosen the 2 union nuts.

    5. Remove the fuel filter to injection pump fuel pipe.

  87. REMOVE NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY


    1. A01CIVD

      Remove the nut and the fuel pipe clamp.

    2. Remove the 2 union bolts, 4 gaskets and No. 3 nozzle leakage pipe sub-assembly.

  88. REMOVE COMMON RAIL ASSEMBLY


    1. A01CIXW

      Disconnect the fuel pressure sensor connector.

    2. Loosen the clip and separate the fuel hose.

    3. Remove the 2 bolts and the common rail assembly.

  89. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNN

      Remove the 2 union bolts and 5 gaskets.

    2. Remove the fuel return pipe sub-assembly.

  90. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01CIH3

      Disconnect the 2 connectors.

    2. Remove the bolt, and then separate the holder clip.

    3. A01CIHL

      Remove the 4 bolts and the supply pump assembly.

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

  91. REMOVE INTAKE AIR TEMPERATURE SENSOR


    1. A01CHH8

      Disconnect the intake air temperature sensor connector.

    2. Remove the bolt.

    3. Disconnect the wire harness clamp.

    4. Remove the bracket from the intake air temperature sensor connector.

    5. A01CIHV

      Using a union nut wrench, remove the intake air temperature sensor and gasket.

      Note

      Do not damage the intake air temperature sensor.

  92. REMOVE INTAKE MANIFOLD


    1. A01CIOK

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