ENGINE UNIT (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE GENERATOR ASSEMBLY


    1. A01DU38

      Remove the 2 bolts and generator.

  2. REMOVE GENERATOR BRACKET


    1. A01DNLP

      Remove the bolt and generator bracket.

  3. REMOVE IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01DRG9

      Remove the bolt, pulley plate, idle pulley and spacer.

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


    1. A01DSQ2

      Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  5. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01DS8Y

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  6. REMOVE NO. 1 FUEL PIPE


    1. A01DUF8E01
      Text in Illustration
      *1 No. 2 Fuel Pipe

      Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

  7. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01DN79

      Remove the 2 bolts and No. 2 exhaust manifold heat insulator from the turbine outlet elbow.

  8. REMOVE TURBINE OUTLET ELBOW STAY


    1. A01DQD9

      Remove the 2 bolts and turbine outlet elbow stay from the No. 2 turbine outlet elbow and cylinder block sub-assembly.

  9. REMOVE NO. 2 TURBINE OUTLET ELBOW


    1. A01DQGW

      Remove the 3 nuts, No. 2 turbine outlet elbow and gasket from the turbine outlet elbow.

  10. REMOVE FUEL PIPE CLAMP


    1. A01DRJK

      Remove the bolt and fuel pipe clamp from the turbine outlet elbow.

  11. REMOVE NO. 11 WATER BY-PASS HOSE


    1. A01DM6P

      Disconnect the exhaust fuel addition injector connector.

    2. Slide the 2 clamps and remove the No. 11 water by-pass hose from the turbine outlet elbow.

  12. REMOVE TURBINE OUTLET ELBOW


    1. A01DPZ1E01
      Text in Illustration
      *1 No. 4 Water By-pass Pipe
      *2 No. 12 Water By-pass Hose
      *3 Turbine Outlet Elbow
      *4 Gasket
      *5 Union Bolt

      Remove the union bolt and gasket from the turbine outlet elbow.

    2. Slide the clamp and remove the No. 4 water by-pass pipe from the No. 12 water by-pass hose.

    3. Remove the 3 nuts, turbine outlet elbow and gasket from the turbocharger sub-assembly.

  13. REMOVE VENTILATION PIPE


    1. A01DQZ6

      Type A

      Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.

    2. A01DM23E01
      Text in Illustration
      *A Type A
      *B Type B

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.

  14. REMOVE NO. 1 TURBO INSULATOR


    1. A01DST7

      Remove the 2 bolts and No. 1 turbo insulator from the turbocharger sub-assembly.

  15. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  16. DISCONNECT ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A01DNJO

      Remove the bolt.

    2. Disconnect the engine oil level dipstick guide from the cylinder block sub-assembly.

  17. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01DQB0E01
      Text in Illustration
      *A Type A
      *B Type B
      *1 No. 1 Turbo Water Hose
      *2 No. 3 Turbo Water Hose

      Slide the 2 clamps and disconnect the No. 1 turbo water hose from the No. 2 water by-pass pipe.

    2. Type B

      Slide the clamp and disconnect the No. 3 turbo water hose from the compressor inlet elbow.

  18. DISCONNECT NO. 3 TURBO WATER HOSE


    1. Slide the clamp and remove the No. 3 turbo water hose from the No. 2 water by-pass pipe.

  19. REMOVE TURBOCHARGER STAY


    1. A01DQXY

      Remove the 2 bolts, nut and turbocharger stay from the turbocharger sub-assembly and cylinder block.

  20. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01DN50

      Remove the bolt and wire harness clamp bracket from the cylinder block.

  21. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01DT27E01

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets.

      Note

      Do not loosen the nut labeled A in the illustration.

  22. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


    1. A01DQCT

      Remove the 8 nuts and 8 plate washers from the exhaust manifold with turbocharger sub-assembly.

    2. Remove the exhaust manifold with turbocharger sub-assembly and gasket.

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A01DOUH

      Remove the bolt and engine oil level dipstick guide.

  24. REMOVE COMPRESSOR ELBOW STAY


    1. A01DTYH

      Remove the 3 bolts and compressor elbow stay.

  25. REMOVE NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01DMZ4

      Disconnect the 3 hoses.

    2. Remove the 2 bolts, nut and No. 5 water by-pass pipe.

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


    1. A01DPR0

      Remove the bolt, nut and No. 2 water by-pass pipe.

  27. REMOVE NO. 2 ENGINE COVER BRACKET


    1. A01DPHW

      Remove the 2 bolts and No. 2 engine cover bracket.

  28. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01DNLX

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and No. 3 vacuum transmitting pipe.

  29. REMOVE NO. 1 VACUUM PIPE


    1. A01DUIU

      Remove the bolt and No. 1 vacuum pipe.

  30. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A01DSTY

      Remove the No. 2 cylinder block insulator from the front No. 1 engine mounting bracket RH.

  31. REMOVE WATER INLET


    1. A01DQ5L

      Disconnect the connector and remove the 3 bolts and water inlet.

  32. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  33. REMOVE NO. 3 CYLINDER BLOCK INSULATOR


    1. A01DTHM

      Detach the clip and remove the No. 3 cylinder block insulator.

  34. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01DLX4

      Remove the 4 bolts and engine oil level sensor.

    2. Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Tech Tips

      Remove only the outer part of the gasket.

  35. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01DOSU

      Disconnect the engine coolant temperature sensor connector.

    2. Remove the engine coolant temperature sensor.

    3. Remove the gasket from the engine coolant temperature sensor.

  36. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A01DR2J

      Remove the bolt and oil pressure switching valve.

  37. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DTSI

      Remove the bolt and camshaft position sensor.

  38. REMOVE CRANKSHAFT POSITION SENSOR


    1. Detach the 2 wire harness clamps (A, B).

    2. Disconnect the crankshaft position sensor connector.

    3. Detach the crankshaft position sensor connector from the No. 1 vacuum transmitting pipe.

    4. Remove the clamp.

      Note


      • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

      • Do not reuse the clamp.

    5. Remove the bolt and bracket (clamp).

    6. Remove the bolt and crankshaft position sensor.

    7. Detach the 2 wire harness clamps from the bracket (clamp).

      A01DTTGE01
      Text in Illustration
      *1 Clamp *2 Bracket (Clamp)
      *3 Wire Harness Clamps (A) *4 Wire Harness Clamps (B)

  39. REMOVE VACUUM PUMP ASSEMBLY


    1. Remove the bolt and bracket.

    2. A01DU2OE01

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

  40. REMOVE VANE PUMP ASSEMBLY


    1. A01DSPC

      Remove the 2 nuts, vane pump and O-ring.

  41. REMOVE NO. 1 TIMING BELT COVER


    1. A01DT7SE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  42. REMOVE TIMING BELT


    1. A01DT33E05
      Text in Illustration
      *1 Timing Mark

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

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A01DMWCE01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A01DO9SE02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.

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

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


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

  44. REMOVE CRANKSHAFT PULLEY


    1. A01DMRSE01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01DLY5E01

      Using SST, remove the pulley bolt and crankshaft pulley.

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

  45. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DTWE

      Disconnect the throttle control motor connector.

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

  46. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01DUFS

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  47. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A01DQAM

      Remove the bolt and emission control valve bracket.

  48. REMOVE THROTTLE BODY BRACKET


    1. A01DPGW

      Remove the 3 bolts and throttle body bracket.

  49. REMOVE NO. 1 GAS FILTER


    1. A01DP2T

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  50. REMOVE GAS FILTER BRACKET


    1. A01DMQK

      Detach the clamp and disconnect the wire harness.

    2. A01DSGE

      Remove the bolt and gas filter bracket.

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


    1. A01DRLR

      Remove the 4 bolts and No. 2 cylinder head cover.

  52. REMOVE NO. 1 VACUUM TRANSMITTING PIPE


    1. A01DQGH

      Disconnect the vacuum hose from the intake manifold.

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

  53. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A01DTVF

      Disconnect the 3 vacuum switching valve connectors.

    2. A01DQV1

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DPF0

      Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.

    4. A01DO5A

      Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    5. A01DMMC

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  54. REMOVE WATER BY-PASS HOSE


    1. Detach the 4 water by-pass hose clamps.

    2. Disconnect the No. 7 water by-pass hose labeled A in the illustration.

    3. Disconnect the No. 4 water by-pass hose labeled B in the illustration.

    4. Disconnect the No. 3 water by-pass hose labeled C in the illustration.

    5. Disconnect the No. 8 water by-pass hose labeled D in the illustration.

    6. Disconnect the No. 6 water by-pass hose labeled E in the illustration.

    7. Disconnect the No. 5 water by-pass hose labeled F in the illustration.

      A01DR6EE01

  55. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DT9L

      Remove the bolt and No. 2 injection pipe clamp.

    2. A01DUVSE01
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  56. REMOVE WIRING HARNESS CLAMP BRACKET


    1. Disconnect the glow plug connector.

    2. A01DQ7X

      Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.

    3. A01DTDD

      Remove the bolt and wiring harness clamp bracket.

  57. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DN54

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

    2. A01DOID

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

    3. A01DR7WE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  58. REMOVE AIR CONNECTOR STAY


    1. A01DN58

      Remove the 3 bolts and air connector stay.

  59. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER


    1. Remove the 2 nuts, the 5 bolts and the electric EGR control valve with No. 2 EGR valve and EGR cooler.

    2. Remove the 2 gaskets from the cylinder head and intake manifold.

      A01DT81

  60. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01DUIF

      Remove the 2 nuts, bolt and intake air connector together with the electric EGR control valve.

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

  61. REMOVE EGR VALVE ADAPTER


    1. A01DMXP

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  62. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A01DRIC

      Remove the bolt, No. 2 EGR valve and gasket.

  63. REMOVE EGR COOLER INSULATOR


    1. A01DTXVE01
      Text in Illustration
      *1 No. 2 EGR Cooler Insulator
      *2 No. 1 EGR Cooler Insulator

      Remove the 2 EGR cooler insulators from the EGR cooler.

  64. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DSLU

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01DP3CE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  65. REMOVE NO. 2 FUEL PIPE


    1. A01DO4F

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A01DQPB Union Bolt
      A01DMKT Fuel Check Valve

    2. Remove the fuel check valve, gasket and No. 2 fuel pipe.

  66. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DPHI

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A01DMKT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  67. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNWG

      Remove the 3 bolts.

      Text in Illustration
      A01DMKT Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  68. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the 2 vacuum switching valve connectors.

    2. A01DMFA

      Disconnect the 3 vacuum hoses, and then remove the 2 bolts and vacuum control valve set.

  69. REMOVE INTAKE PIPE STAY


    1. A01DRKX

      Remove the bolt and intake pipe stay.

  70. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01DPSM

      Remove the intake manifold insulator.

  71. REMOVE INTAKE MANIFOLD


    1. A01DP4B

      Detach the sensor wire connector clamp from the intake manifold.

    2. A01DPG9

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

  72. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. Disconnect the No. 1 glow plug connector from the wire harness.

    2. A01DPSG

      Remove the 4 screw grommets.

    3. A01DNFC

      Remove the 4 nuts and No. 1 glow plug connector.

  73. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A01DMQU

  74. REMOVE GLOW PLUG ASSEMBLY

    A01DTLO

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

  75. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DPTWE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  76. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector.

    2. A01DMXK

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.

  77. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A01DTAI

      Remove the No. 2 intake manifold insulator.

  78. REMOVE INJECTION PUMP INSULATOR

    A01DTKY

  79. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A01DQ30

      Remove the 2 bolts and No. 1 injection pump protector.

  80. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01DMX0E01

      Remove the 4 bolts indicated by the arrows in the illustration.

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

    3. A01DPYKE05

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    4. A01DOAZ

      Loosen the 2 nuts.

    5. A01DSTAE03

      Using SST, disconnect the fuel supply pump from the injection gear.

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

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

  81. REMOVE WATER OUTLET


    1. A01DMCC

      Remove the 2 bolts, gasket and water outlet.

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


    1. A01DPF8

      Disconnect the vacuum hose.

    2. Remove the 2 nuts and No. 2 vacuum transmitting pipe.

  83. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. A01DPU3

      Remove the 13 bolts and oil cooler cover.

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


    1. A01DTF1

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

  85. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. A01DMUC

      Remove the 4 bolts and No. 1 oil pan cover.

  86. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET


    1. A01DO91E01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Remove the 8 bolts and 2 front No. 1 engine mounting brackets.