ENGINE ASSEMBLY (w/o DPF) REMOVAL


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE FRONT WHEELS

  4. DRAIN ENGINE COOLANT

    A01BCB6E01

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator reserve tank cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the engine oil cooler cover), and drain the coolant.

    4. Tighten the engine drain plug (on the radiator).

    5. Tighten the engine drain plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the drain plug from the oil pan and drain the engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  6. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  7. REMOVE FRONT DOOR SCUFF PLATE RH

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the engine service hole sub cover assembly.

  9. REMOVE NO. 2 ENGINE SERVICE HOLE COVER

    A01BG4E

    1. Roll up the carpet.

    2. A01BD0S

      Remove the 3 bolts and No. 2 engine service hole cover.

  10. LOOSEN FAN PULLEY


    1. Loosen the 4 nuts from the fan pulley.

  11. REMOVE FAN & GENERATOR V BELT


    1. A01BERGE01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  12. REMOVE FAN PULLEY


    1. Remove the 4 nuts and fan pulley.

  13. REMOVE FENDER APRON MUDGUARD SEAL RH


    1. Disengage the 4 clips and remove the fender apron mudguard.

  14. SEPARATE TAIL EXHAUST PIPE ASSEMBLY (for Long Wheelbase)

    A01BI3O

    1. Remove the 2 bolts and 2 nuts, and separate the tail exhaust pipe.

    2. A01BHA3

      Remove the gasket.

  15. SEPARATE CENTER EXHAUST PIPE ASSEMBLY (for Super Long Wheelbase)

    A01BB6L

    1. Remove the 2 bolts and 2 nuts, and separate the center exhaust pipe.

    2. A01BHA3

      Remove the gasket.

  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    A01BH7S

    1. Remove the 2 bolts and the 2 compression springs.

    2. Remove the hanger and the front exhaust pipe.

    3. A01BAYV

      Remove the gasket.

  17. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFYF

      Remove the 2 hose clamps, bolt and compressor outlet elbow.

  18. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01BHN9

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  19. DISCONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01BBX8

      Disconnect the turbocharger motor connector.

  20. REMOVE AIR TUBE ASSEMBLY


    1. A01BAB5E02

      Remove the 2 hose clamps, 2bolts, air tube assembly and No. 1 air cleaner hose.

  21. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01BETM

      Disconnect the turbocharger stroke sensor connector.

  22. SEPARATE W/ PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    A01BHBG

    1. Disconnect the connector.

    2. Remove the 4 bolts and separate the compressor.

  23. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE01

      Remove the 4 bolts and compressor bracket.

  24. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Remove the bolt, washers and idle pulley assembly.

  25. REMOVE GENERATOR BRACKET


    1. A01BCXBE01

      Remove the 2 bolts, then remove the generator bracket.

  26. REMOVE GENERATOR ASSEMBLY


    1. A01BCVDE01

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the bolt and generator.

  27. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BDED

      Remove the 4 bolts and belt tensioner assembly.

  28. REMOVE VENTILATION PIPE SUB-ASSEMBLY


    1. A01BHQ5

      Remove the bolt and ventilation pipe sub-assembly.

  29. REMOVE NO. 1 TURBO INSULATOR


    1. A01BEFA

      Remove the 2 bolts and turbo insulator.

  30. REMOVE EXHAUST MANIFOLD HEAT INSULATOR


    1. A01BG6A

      Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

  31. REMOVE NO. 1 TURBO WATER HOSE


    1. A01BC20

      Loosen the 2 clips and disconnect the 2 turbo water hoses.

  32. REMOVE TURBINE OUTLET ELBOW


    1. A01BE8V

      Remove the 3 nuts, turbine outlet elbow and gasket.

  33. REMOVE TURBOCHARGER STAY


    1. A01BCUS

      Remove the 2 bolts and nut to remove the turbocharger stay.

  34. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BCPXE01

      Remove the 2 bolts, 2 nuts and union bolt, then remove the turbo oil inlet pipe sub-assembly and gasket.

      Note

      Do not loosen the nut labeled A, If mistakenly loosened, replace the turbocharger.

  35. REMOVE EXHAUST MANIFOLD


    1. Remove the 8 nuts and exhaust manifold from the cylinder head.

  36. DISCONNECT OIL RETURN HOSE


    1. Disconnect the oil return hose from the intake manifold.

  37. DISCONNECT NO. 4 AIR HOSE


    1. Remove the clamp, and disconnect the No. 4 air hose from the diesel throttle body.

  38. DISCONNECT RADIATOR HOSE INLET


    1. Remove the clamp, and disconnect the radiator inlet hose from the water inlet.

  39. DISCONNECT NO. 4 RADIATOR HOSE


    1. Remove the clamp, and disconnect the No. 4 radiator hose from the water outlet.

  40. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. Remove the clamp, and disconnect the No. 3 water by-pass hose from the water by-pass pipe.

  41. DISCONNECT NO. 2 FUEL HOSE


    1. Remove the clamp, and disconnect the No. 2 fuel hose from the nozzle leakage pipe No. 2.

  42. DISCONNECT NO. 1 FUEL HOSE


    1. Remove the clamp, and disconnect the No. 1 fuel hose from the injection pump assembly.

  43. DISCONNECT VACUUM HOSE


    1. A01BASG

      Disconnect the vacuum hose from the vacuum pump assembly.

  44. DISCONNECT ENGINE WIRE


    1. Remove the wire harness support from the ECM.

    2. Disconnect the connectors from the ECM.

    3. Disconnect the clamps from the engine wire and earth cable.

    4. A01BFD1E03

      Remove the 4 connectors and nut as shown in the illustration.

  45. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Remove the 2 bolts, and separate the vane pump oil reservoir assembly.

  46. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Refer to the procedures under "REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY" Click here.

  47. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Refer to the procedures under "REMOVE AUTOMATIC TRANSMISSION ASSEMBLY" Click here.

  48. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A01BAUVE01

      Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

    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 assembly.

      Note

      Do not drop the clutch disc assembly.

  49. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note

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

  50. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01BDZSE03

      Fix the crankshaft with SST.

      SST
      09213-58013
      09330-00021
    2. A01BGK5E02

      For manual transmission:

      Remove the 8 bolts and remove the flywheel.

    3. For automatic transmission:

      Remove the 8 bolts, and remove the drive plate spacer rear, drive plate and flywheel.

  51. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  52. REMOVE SPEED SENSOR FRONT LH (w/ ABS)


    1. A01BFZEE01

      Remove the 2 bolts, and separate the speed sensor from the steering knuckle.

      Note


      • Be careful not to damage the speed sensor.

      • Prevent foreign matter from adhering to the speed sensor.

  53. REMOVE SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  54. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A01BB1EE01

      Remove the 2 bolts, and disconnect the brake caliper assembly.

      Note

      Use a wire or an equivalent to keep the brake caliper from hanging down by the flexible hose.

  55. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  56. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. A01BCPDE01

      Remove the cotter pin and loosen the nut.

      SST
      09628-62011

      Note

      Do not remove the nut.

    2. Using SST, separate the steering knuckle from the suspension upper arm and remove the nut.

      Note


      • Fix the steering knuckle with a wire so that the flexible hose does not receive excessive force.

      • Do not damage the ball joint dust cover.

  57. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  58. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT LH


    1. A01BCXLE02

      Remove the bolt and separate the front shock absorber from the front suspension lower arm.

  59. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  60. SEPARATE STEERING TORQUE SHAFT ASSEMBLY


    1. A01BH0EE01

      Loosen bolt (A) and remove bolt (B), then slide the steering torque shaft assembly.

      Tech Tips


      • Do not remove bolt (A).

      • Do not disconnect the steering torque shaft assembly from the power steering link assembly.

    2. A01BG7RE01

      Put matchmarks on the steering torque shaft assembly and the power steering link assembly.

    3. Separate the steering torque shaft assembly from the power steering link assembly.

  61. REMOVE ENGINE ASSEMBLY


    1. Using the engine lifter, hold the engine assembly and separate the rear engine mount.

    2. A01BCFWE02

      Remove the 16 bolts and remove the stabilizer brackets and front suspension cross member.

    3. Remove the engine assembly w/ transmission out of the vehicle slowly and carefully.

  62. REMOVE ENGINE WIRE


    1. Disconnect the engine wire from the engine assembly.

  63. INSTALL ENGINE HANGERS


    1. A01BCX2E01

      Install the 2 engine hangers in the correct direction.

      Torque:
      No. 1 engine hanger
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
      No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
      Parts name Parts No.

      Engine hanger No.1 upper

      Bolt

      12284-30020

      91512-61014

      Engine hanger No.2

      Bolt

      12282-67020

      91642-81030

      Note

      Use a new bolt for the engine hanger.

  64. SEPARATE NO. 1 OIL RESERVOIR TO PUMP HOSE


    1. A01BF46E01

      Remove the clip and separate the No.1 oil reservoir to pump hose.

  65. SEPARATE PRESSURE FEED TUBE ASSEMBLY


    1. A01BBC6E01

      Remove the union bolt and separate the pressure feed tube assembly.

  66. REMOVE FRONT SUSPENSION CROSS MEMBER


    1. Hold the engine with the engine sling device and chain block.

    2. Remove the 4 bolts from the front suspension cross member.

    3. Remove the engine assembly by operating the engine sling device and chain block.

  67. INSTALL ENGINE STAND

  68. REMOVE VANE PUMP ASSEMBLY


    1. A01BEQHE01

      Remove the 2 nuts and the vane pump assembly.

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

  69. REMOVE TIMING GEAR COVER INSULATOR

  70. REMOVE VACUUM PUMP ASSEMBLY


    1. A01BAO8

      Remove the 2 nuts, and then remove the vacuum pump and 2 O-rings.

  71. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the wire harness clamp.

    2. A01BDL8

      Remove the 6 bolts and timing belt cover.

  72. REMOVE TIMING BELT


    1. A01BB9ZE03

      Set the No. 1 cylinder to TDC/ compression.


      1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

        Tech Tips

        If reusing the timing belt, draw a direction arrow on the belt (in the direction of engine revolution) and place matchmarks on the pulleys and belt as shown in the illustration.

    2. A01BHFHE01

      Alternately loosen the 2 bolts, and remove the timing belt tensioner.

    3. A01BFILE02

      Remove the timing belt.

      Tech Tips


      • When turning the camshaft with the timing belt removed, first turn the crankshaft 90° counterclockwise to lower the piston.

      • When installing the timing belt, first return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks.

  73. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. A01BH1Y

      Using a 10 mm socket hexagonal wrench, remove the bolt, plate washer and timing belt idler No.1.

  74. REMOVE CRANKSHAFT POSITION SENSOR

    A01BB55

    1. Disconnect the crankshaft position sensor connector.

    2. Separate the connector from the No. 1 vacuum pipe .

    3. A01BFNV

      Separate the 3 wire harness clamps.

    4. Remove the bolt and the crankshaft position sensor.

  75. REMOVE CAMSHAFT POSITION SENSOR

    A01BERQ

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  76. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    A01BA8Q

    1. Disconnect the 2 throttle body connectors.

    2. A01BEHN

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

    3. Remove the gasket from the intake air connector.

  77. REMOVE EGR COOLER ASSEMBLY

    A01BH3G

    1. Loosen the clip and disconnect the No. 4 water by-pass hose.

    2. Loosen the clip and disconnect the No. 2 water by-pass hose.

    3. A01BDC3

      Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.

  78. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01BBVC

      Disconnect the intake air temperature sensor connector.

    2. Remove the vacuum regulating valve.


      1. A01BDUS

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. A01BH0B

        Remove the 2 bolts and the vacuum regulating valve.

    3. A01BBMB

      Remove the electric EGR control valve with the sensor.


      1. Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. A01BHKK

        Disconnect the EGR valve position sensor connector.

      4. Disconnect the vacuum hose from the electric EGR control valve.

      5. Remove the bolt, 2 nuts and intake air connector assembly.

      6. A01BACYE02

        Remove the 2 gaskets and electric EGR control valve from the intake air connector.

  79. REMOVE MANIFOLD STAY


    1. Remove the bolt and manifold stay.

  80. REMOVE OIL LEVEL GAUGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  81. REMOVE FUEL INJECTION PIPE

    A01BALH

    1. Disconnect the fuel injector connector and harness clamps.

    2. Remove the 3 bolts.

    3. A01BEJA

      Remove the 2 bolts and remove the 2 No. 2 injection pipe clamps.

    4. A01BFN0

      Using SST, remove the 4 injection pipes.

      SST
      09023-12701

  82. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01BC23

    1. Remove the 2 clamp bolts.

    2. A01BDF3

      Using SST, loosen the 2 union nuts and remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  83. REMOVE COMMON RAIL ASSEMBLY

    A01BFUS

    1. Disconnect the 2 connectors from the common rail.

    2. Disconnect the fuel hose.

    3. A01BEK0

      Remove the 2 bolts and remove the common rail.

  84. REMOVE NO. 2 CAMSHAFT TIMING PULLEY FLANGE


    1. A01BCD7E01

      Remove the 4 bolts and the No. 2 camshaft timing pulley flange.

  85. REMOVE PUMP DRIVE SHAFT PULLEY

  86. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY

    A01BCD7

    1. Remove the 4 bolts.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    3. A01BHHYE01

      Using SST, remove the supply pump gear set nut and O-ring while holding the crankshaft pulley.

      SST
      09213-58013
      09330-00021

    4. Disconnect the 2 fuel hoses.

    5. Disconnect the 2 connectors and wire harness.

    6. A01BGD8

      Loosen the 2 nuts as shown in the illustration.

    7. A01BC8XE01

      Using SST, disengage the fuel supply pump from the supply pump gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

    8. Remove the 2 nuts and fuel supply pump from the engine.

    9. Remove the O-ring from the fuel supply pump.

    10. Remove the pulley key from the fuel supply pump.

  87. REMOVE CRANKSHAFT PULLEY


    1. A01BHJJE01

      Using SST, remove the pulley bolt.

      SST
      09213-58013
      09330-00021
    2. A01BE2GE01

      Using SST, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply oil or grease to the threads and tip of SST (center bolt) before using SST.

  88. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A01BI3F

    1. Disconnect the 3 fuel hoses.

    2. Remove the 2 union bolts and 2 gaskets.

    3. A01BG79

      Remove the 3 bolts and the No. 2 nozzle leakage pipe.

  89. REMOVE FUEL COOLER


    1. Disconnect the 2 water by-pass hoses.

    2. Remove the 2 bolts and fuel cooler.

  90. REMOVE NO. 2 WATER BY-PASS PIPE


    1. Remove the 2 nuts and bolt, and then remove the No. 2 water by-pass pipe.

    2. Remove the gasket.

  91. REMOVE WATER INLET


    1. A01BFN3

      Remove the 3 bolts and water inlet.

  92. REMOVE THERMOSTAT


    1. Remove thermostat and gasket.

  93. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

  94. REMOVE NO. 1 GLOW PLUG CONNECTOR

    A01BE1N

    1. Remove the screw grommet and nut and separate the wire harness from the No. 1 glow plug connector.

    2. Remove the 4 screw grommets and 4 nuts and remove the No.1 glow plug connector.

  95. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    A01BFOP

    1. Remove the No. 2 intake manifold Insulator.

  96. REMOVE GLOW PLUG ASSEMBLY

    A01BB48

    1. Remove the 4 glow plugs.

  97. REMOVE INTAKE MANIFOLD

    A01BAG7

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

  98. REMOVE WATER OUTLET


    1. Remove the 2 bolts, water outlet and gasket.

  99. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Disconnect the vacuum hose from No. 2 vacuum transmitting pipe.

    2. Remove the nut and bolt, and then remove the No. 1 vacuum transmitting pipe.

  100. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Remove the 2 nuts, bolt and No. 2 vacuum transmitting pipe.

  101. REMOVE OIL FILTER SUB-ASSEMBLY

    A01BBU2E01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Position the drain oil container to collect the oil from the oil filter.

  102. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01BABQ

    1. Disconnect the oil pressure switch connector.

    2. Disconnect the 2 oil filter drain hoses.

    3. A01BHZ8

      Remove the 13 bolts, 2 nuts and separate the No. 2 vacuum transmitting pipe.

    4. Remove the oil cooler cover and gasket from the cylinder block.

  103. REMOVE DIESEL ENGINE WATER TEMPERATURE SENSOR


    1. Using a 17 mm deep socket wrench, remove the water temperature sensor.

  104. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH


    1. A01BC80E01

      Remove the 4 bolts and No. 1 engine mounting bracket.

  105. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT RH


    1. A01BDC4E01

      Remove the 4 bolts and No. 1 engine mounting bracket.