ENGINE UNIT REMOVAL


  1. REMOVE ENGINE ASSEMBLY

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  2. REMOVE ENGINE WIRE

  3. REMOVE TIMING BELT

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  4. REMOVE PUMP DRIVE SHAFT PULLEY

  5. REMOVE VACUUM PUMP ASSEMBLY


    1. Remove the 2 nuts and vacuum pump.

    2. Remove 2 the O-rings.

  6. REMOVE CRANKSHAFT PULLEY


    1. A01KHSEE01

      Using SST, remove the pulley bolt and plate.

      SST
      09213-58012
      09330-00021
    2. A01KHTDE01

      Using SST, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  7. REMOVE EGR PIPE SUB-ASSEMBLY NO.1


    1. Remove the 2 nuts.

    2. Remove the EGR control valve, EGR pipe sub-assembly and 2 gaskets.

  8. REMOVE VSV ASSEMBLY


    1. Remove the 2 bolts and VSV assembly.

  9. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01KGCJE01

      Using SST, remove the oil filter.

      SST
      09228-10002

      Tech Tips

      As the oil in the filter flows out through the drain hose, place the drain oil container under the drain hose.

    2. Clean the oil filter contact surface on the oil filter mounting.

    3. Lubricate the filter rubber gasket with clean engine oil.

  10. REMOVE INJECTION PIPE SET


    1. Remove the 2 nuts and injection pipe clamp No. 3.

    2. Remove the bolt and injection pipe clamp No. 2.

    3. Remove the bolt and injection pipe clamp No. 1.

    4. A01KHC6

      Using a 17 mm union nut wrench, loosen the injection pipe unions of common rail side.

    5. Using a 17 mm union nut wrench, loosen the injection pipe unions of injector side.

      Note


      • After removing the fuel pipe, affix the gum tape to the common rail for preventing dust.

      • After removing the fuel pipe, put a vinyl bag and rubber band to prevent mixing foreign objects over the injectors inlet.

  11. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01KICG

    1. Remove the bolt and injection pipe clamp No. 2.

    2. Using a union wrench 17mm, loosen the fuel inlet union of common rail side.

    3. Using a union wrench 17 mm, loosen the fuel inlet pipe union of pump side.

    4. Remove the inlet pipe sub-assembly.

      Note

      After removing the fuel pipe, affix the gum tape to the pump, common rail, and the whole injector installation area of the cylinder head cover for preventing dust.

  12. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2

    A01KHU4

    1. Disconnect the fuel hose from the nozzle leakage pipe assembly No. 2.

    2. Remove the 2 bolts, 2 union bolts, check valve, nozzle leakage pipe assembly No. 2 and 3 gaskets.

  13. REMOVE INTAKE MANIFOLD


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

  14. REMOVE TURBO WATER HOSE NO.1

  15. REMOVE WATER OUTLET

  16. REMOVE GLOW PLUG ASSEMBLY

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  17. REMOVE COMMON RAIL ASSEMBLY

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  18. REMOVE INJECTION PUMP ASSEMBLY

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  19. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. Disconnect the oil pressure switch connector.

    2. Disconnect the engine coolant temperature sensor connector.

    3. Remove the 2 nuts and disconnect the vacuum pipe.

    4. Remove the 13 bolts, oil cooler cover sub-assembly and gasket.

  20. REMOVE VACUUM PIPE

  21. REMOVE VENTILATION HOSE HEAT INSULATOR

  22. REMOVE EXHAUST MANIFOLD


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

  23. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY NO.2

  24. REMOVE WATER INLET

  25. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the bolt and level gauge with guide assembly.

  26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the 6 bolts and alternator with belt tensioner assembly.

  27. REMOVE CRANK POSITION SENSOR

  28. REMOVE CRANK POSITION NO.2 SENSOR

  29. REMOVE WATER TEMPERATURE SENDER GAGE ASSEMBLY

  30. REMOVE ENGINE OIL LEVEL SENSOR

  31. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH

  32. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH