ENGINE UNIT REMOVAL


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE VANE PUMP DRIVE PULLEY


    1. Remove the 4 bolts, vane pump drive pulley and the vane pump drive pulley spacer.

    2. w/ A/C:

      Remove the 4 bolts, vane pump drive pulley and the crankshaft pulley No. 2.

  3. REMOVE CRANKSHAFT PULLEY


    1. A01KEW9E01

      Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01KI1LE01

      Using SST, remove the pulley.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  4. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Remove the 11 bolts, washers, timing belt cover and 2 gaskets.

    2. Remove the collar from the timing pointer.

  5. REMOVE TIMING BELT

    A01KERN

    Tech Tips

    If re-using the timing belt, draw a direction arrow on the timing belt (in direction of engine revolution), and place matchmarks on the pulleys and timing belt.


    1. Remove the timing belt. Click here

  6. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Remove the 3 nuts and bolt, intake air connector and gasket.

  7. REMOVE INTAKE AIR CONNECTOR BRACKET

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  9. REMOVE CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No.2)


    1. Remove the 4 nuts, plate washers and the cylinder head cover.

  10. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONER)

  11. REMOVE IDLE PULLEY BRACKET (W/ AIR CONDITIONER)

  12. REMOVE GENERATOR ASSEMBLY

    Click here

  13. REMOVE FAN BELT ADJUSTING BAR (W/O AIR CONDITIONER)

  14. REMOVE INJECTION PIPE CLAMP

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.4

  16. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.3

  17. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.2

  18. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.1

  19. REMOVE INJECTION PUMP DRIVE PULLEY


    1. Using SST, remove the injection pump drive pulley installation nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021   ( 09330-00030 )

    2. Using SST, remove the injection pump drive pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05010 )

      Note

      The tip and threads of the center bolt 100 should be coated with lubricant.

  20. REMOVE INJECTION PUMP ASSEMBLY

    Click here

  21. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH

  22. REMOVE PUMP BRACKET

  23. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1

  24. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/EGR)


    1. A01KH4B

      Loosen the union nut holding the EGR valve to the EGR pipe.

    2. Remove the 2 bolts, 4 nuts, EGR valve and EGR adapter and gasket.

    3. Remove the 2 bolts and EGR pipe.

  25. REMOVE EXHAUST PIPE ASSEMBLY FRONT


    1. Remove the 3 nuts, exhaust pipe and gasket.

  26. REMOVE EXHAUST MANIFOLD


    1. Remove the 6 bolts, 2 nuts, exhaust manifold and gasket.

  27. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Using SST, remove the oil filter.

      SST
      09228-10002

  28. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    A01KFG3

    1. Remove the union bolt and gasket, and disconnect the vacuum pump oil inlet hose.

    2. Remove the 10 bolts, 2 nuts, oil filter bracket and gasket.

  29. REMOVE GLOW PLUG NO.1 CONNECTOR

  30. REMOVE GLOW PLUG ASSEMBLY

    Click here

  31. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Remove the 4 nuts, nozzle leakage pipe assembly and washer.

  32. REMOVE NOZZLE HOLDER AND NOZZLE SET


    1. Using SST, remove the set of holder and nozzle.

      SST
      09268-64010   ( 09268-64020 )

    2. Remove the nozzle sheet and nozzle sheet gasket.

  33. REMOVE WATER OUTLET HOUSING


    1. A01KHGQE01

      w/ ACSD:

      Disconnect the water bypass hose from the water housing.

    2. Disconnect the water temperature sender gauge connector.

    3. Remove the 3 bolts, the water outlet, outlet housing assembly and gasket.

  34. REMOVE INTAKE MANIFOLD


    1. A01KFMWE01
      Text in Illustration
      *1 Oil Dipstick Guide Clamp

      Remove the bolt and nut, accelerator link and hose clamp (w/ ACSD).

    2. Remove the 6 bolts, 2 nuts, 2 engine wire brackets, oil dipstick guide clamp, intake manifold assembly and gasket.

  35. REMOVE WATER BY-PASS HOSE UNION

  36. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

  37. REMOVE ENGINE OIL LEVEL SENSOR

  38. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

  39. REMOVE VACUUM PUMP INLET UNION

  40. REMOVE VACUUM PUMP OUTLET UNION