ENGINE UNIT REMOVAL


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


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

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


    1. A01CGZM

      Disconnect the 4 connectors and remove the bolt and wire harness.

    2. Remove the cylinder head cover cushion rubber from the No. 2 cylinder head cover sub-assembly.

    3. Remove the 2 bolts, 2 cylinder head cover cushions and 2 spacers from the No. 2 cylinder head cover sub-assembly.

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

    5. Remove the 4 No. 2 cylinder head cover gaskets from the 4 injector assemblies.

  4. REMOVE EGR VALVE ASSEMBLY

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  5. REMOVE VENTURI ASSEMBLY

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  6. REMOVE NO. 1 INTAKE PIPE


    1. A01CIO8

      Remove the 3 bolts, 2 nuts and No. 1 intake pipe.

  7. REMOVE GLOW PLUG GROUND WIRE (for Cold Area Specification Vehicles)


    1. Remove the 4 screw grommets.

    2. Remove the 4 nuts.

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

  8. REMOVE GLOW PLUG ASSEMBLY (for Cold Area Specification Vehicles)


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

  9. REMOVE BOLT


    1. Remove the 4 bolts from the 4 glow plug holes.

  10. REMOVE VANE PUMP ASSEMBLY

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  11. REMOVE RADIATOR PIPE SUB-ASSEMBLY


    1. A01CHDF

      Remove the 2 bolts and radiator pipe sub-assembly.

    2. Remove the O-ring from the radiator pipe sub-assembly.

  12. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  13. REMOVE IDLE PULLEY BRACKET


    1. A01CGLB

      Remove the 3 bolts and idle pulley bracket.

  14. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01CGMJ

      Remove the 3 bolts and No. 1 compressor mounting bracket.

  15. REMOVE COMMON RAIL ASSEMBLY

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  16. REMOVE INJECTOR ASSEMBLY

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  17. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY

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  18. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHG3E01
      Text in Illustration
      *1 Fuel Return Pipe Sub-assembly
      *2 No. 3 Nozzle Leakage Pipe Sub-assembly
      *3 No. 2 Fuel Return Pipe Sub-assembly
      *4 Fuel Pipe
      *5 No. 4 Fuel Pipe Sub-assembly

      Remove the nut and injection pipe clamp.

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

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


    1. Remove the nut and nozzle leakage clamp.

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

  20. REMOVE NO. 2 FUEL RETURN PIPE SUB-ASSEMBLY


    1. Remove the nut and injection pipe clamp.

    2. Remove the union bolt, gasket and No. 2 fuel return pipe sub-assembly.

  21. REMOVE FUEL PIPE


    1. Remove the union bolt, 3 gaskets and fuel pipe.

  22. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Remove the union bolt, gasket and No. 4 fuel pipe sub-assembly.

  23. REMOVE DIESEL FUEL FILTER ASSEMBLY


    1. A01CGUOE01
      Text in Illustration
      *1 Fuel Filter Drain Plug
      *2 Bleeder Plug

      After loosening the fuel filter drain plug, loosen the bleeder plug and drain the fuel.

      Note

      Place a container, etc. underneath the fuel filter to prevent fuel from spraying.

    2. A01CI5XE01

      Using SST, remove the diesel fuel filter assembly.

      SST
      09228-78010

  24. REMOVE UPPER FUEL FILTER BODY


    1. A01CI2B

      Remove the 2 bolts and upper fuel filter body.

  25. REMOVE VACUUM PIPE


    1. A01CIB7

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

  26. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

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

    2. Remove the 3 gaskets.

  27. REMOVE VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Remove the 2 nuts and vacuum pump assembly.

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

  28. REMOVE FUEL PIPE SUPPORT


    1. A01CJHJ

      Remove the bolt and fuel pipe support.

  29. REMOVE FUEL FILTER BRACKET


    1. A01CIDD

      Remove the 2 bolts and fuel filter bracket.

  30. REMOVE CAMSHAFT POSITION SENSOR


    1. A01CINB

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  31. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CIJX

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  32. REMOVE THERMOSTAT


    1. A01CGW0

      Remove the 3 bolts and water outlet.

    2. Remove the thermostat from the water outlet housing.

    3. Remove the gasket from the thermostat.

  33. REMOVE WATER TEMPERATURE SENDER GAUGE ASSEMBLY


    1. A01CIYI

      Disconnect the engine coolant temperature sensor connector.

    2. A01CI5G

      Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.

  34. REMOVE WATER OUTLET HOUSING


    1. A01CICZ

      Remove the 3 bolts and water outlet housing.

  35. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CGQT

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

    2. Remove the 6 O-rings.

  36. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01CIV9

      Remove the 8 bolts and engine water pump assembly.

  37. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01CH45

      Remove the 2 nuts, 2 engine mounting stabilizers and 2 engine mounting insulators.

  38. REMOVE OIL COOLER ASSEMBLY

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  39. REMOVE EXHAUST MANIFOLD


    1. A01CGMY

      Remove the 8 nuts, 8 spacers and exhaust manifold.

    2. Remove the 4 gaskets.

    3. Replace the 2 stud bolts.

      Tech Tips

      If a stud bolt is deformed or the threads are damaged, replace it.

  40. REMOVE INTAKE MANIFOLD


    1. A01CI83

      Cold Area Specification Vehicles:

      Detach the 2 clamps.

    2. A01CIE9

      Remove the 2 bolts and wire harness clamp bracket.

    3. A01CI60

      Remove the bolt and wire harness clamp bracket.

    4. A01CGRM

      Remove the 8 bolts, 2 nuts and intake manifold.

  41. REMOVE NO. 2 FUEL PIPE SUPPORT


    1. A01CJ8I

      Remove the 2 bolts and No. 2 fuel pipe support.

  42. REMOVE FUEL PIPE SUPPORT


    1. A01CI2E

      Remove the 2 bolts and fuel pipe support.