ENGINE ASSEMBLY REMOVAL


  1. DISCONNECT BATTERY NEGATIVE TERMINAL

  2. REMOVE FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

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  3. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

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  4. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Remove the clip and nut, and then Disconnect the select cable from the transmission.

  5. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Remove the clip and nut, and then Disconnect the shift cable from the transmission.

  6. DISCONNECT TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  7. DISCONNECT PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

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  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and engine service hole sub-cover.

  9. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH

  10. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH

  11. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH

  12. REMOVE FENDER SIDE APRON SUB-ASSEMBLY LH

  13. DRAIN ENGINE COOLANT

  14. REMOVE FAN AND GENERATOR V BELT


    1. Loosen the belt tension by turning the belt tensioner clockwise, and remove the V belt.

  15. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

    A01KHGVE01

  16. DISCONNECT REAR HEATER WATER INLET HOSE A (FROM ENGINE)

  17. REMOVE AIR HOSE NO.1

  18. REMOVE AIR HOSE NO.3

  19. REMOVE HOSE, RADIATOR, NO.2

  20. REMOVE RADIATOR HOSE OUTLET

  21. REMOVE FLUID COUPLING ASSEMBLY


    1. Remove the 2 bolts, and then separate the fan shroud.

    2. Remove the 4 nuts holding the fan with coupling, and also the fan shroud together with fan with coupling.

  22. REMOVE RADIATOR ASSEMBLY

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  23. DISCONNECT FUEL HOSE ALL (ENGINE ROOM)


    1. Disconnect the fuel main hose and return hose.

  24. REMOVE AIR CLEANER PIPE

  25. REMOVE AIR CLEANER HOSE NO.2

  26. REMOVE EXHAUST PIPE ASSEMBLY FRONT

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  27. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  28. REMOVE INTAKE AIR CONNECTOR


    1. A01KFK2

      Disconnect the connector and hose.


      1. Disconnect the throttle control motor connector.

      2. Disconnect the throttle full switch connector.

      3. Disconnect the Intake air temp. sensor connector.

      4. Disconnect the vacuum hose.

    2. Remove the 2 bolts, 2 nuts, gasket and intake air connector with diesel throttle body assembly.

  29. DISCONNECT ENGINE WIRE

  30. REMOVE PROPELLER SHAFT ASSEMBLY REAR



  31. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

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    Tech Tips

    The separation should be done with the hose connected, and then it should be hung with rope.

  32. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    A01KHFIE01

    1. Remove the cotter pin and nut.

    2. Using SST, disconnect the tie rod end from the steering knuckle arm.

      SST
      09610-20012

  33. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Remove the RH side by the same procedures with the LH side.

  34. REMOVE FRONT SPRING BUMPER NO.1


    1. Remove the nut and front spring bumper No. 1 RH and LH.

  35. DISCONNECT STEERING TORQUE SHAFT ASSEMBLY

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  36. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01KGSCE01

      Disconnect the pressure feed tube.

    2. Disconnect the return tube.

    3. Remove 2 bolts and oil reservoir with bracket.

  37. DISCONNECT VANE PUMP ASSEMBLY

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  38. DISCONNECT PRESSURE FEED TUBE ASSEMBLY

  39. REMOVE FRONT SUSPENSION MEMBER ASSEMBLY


    1. Remove the front stabilizer cover RH and LH.

    2. Separate the front shock absorber assembly RH and LH at the lower arm part.

    3. Using an engine lifter to hold the front suspension member assembly, remove the 4 bolts.

    4. Remove the front stabilizer bar, lower arm RH and LH, and front suspension member assembly all together.

  40. REMOVE ENGINE W/TRANSMISSION ASSEMBLY


    1. Using an engine lifter to hold the engine, separate the mount of the transmission.

    2. Separate the parking brake cable No.3 (for vehicles with center brake).

    3. First remove the engine front mounting bracket RH and LH, and then the engine assembly with transmission.

    4. A01KIK6E01
      Text in Illustration
      *a No. 1
      *b No. 2

      Install the 2 engine hangers in the correct direction.

      Part No.
      Parts name Parts No.
      No. 1 engine hanger upper Bolt

      12284-30030

      91512-61014
      No. 2 engine hanger Bolt

      12282-67040

      91642-81030
      Torque:
      No. 1 engine hanger upper
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
      No. 2 engine hanger
      68 N*m  { 694 kgf*cm, 50 ft.*lbf }

    5. Using a chain block and engine sling device, hang up the engine assembly so as not tilt it.

      CAUTION:

      Do not attempt to hang the engine by hooking the chain to any other part.

  41. REMOVE ENGINE WIRE

  42. REMOVE STARTER ASSEMBLY



  43. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY



  44. REMOVE CLUTCH COVER ASSEMBLY


    1. A01KHECE02
      Text in Illustration
      *a Matchmark

      Place the matchmarks on the clutch cover with the one on the flywheel.

    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.

      Note

      Do not drop the clutch disc.

  45. REMOVE CLUTCH DISC ASSEMBLY

    Note

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

  46. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01KF0GE01

      Using SST to fix the crank shaft pulley, remove the 8 bolts and flywheel.

      SST
      09213-58012
      09330-00021

  47. REMOVE REAR END PLATE