ENGINE UNIT (w/o DPF) REMOVAL


  1. REMOVE GENERATOR ASSEMBLY


    1. A01DSSJ

      Remove the 2 bolts and generator.

  2. REMOVE GENERATOR BRACKET


    1. A01DLWN

      Remove the bolt and generator bracket.

  3. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01DPQ1

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

  4. 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.

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01DT8L

      Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.

    3. Remove the O-ring from the engine oil level dipstick guide.

  6. REMOVE COMPRESSOR INLET ELBOW


    1. A01DPZN

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket from the water inlet.

    3. Disconnect the 2 connectors and detach the wire harness clamp.

      A01DTACE01
      Text in Illustration
      *A Type A *B Type B

    4. Slide the clamp and disconnect the No. 2 turbo water hose from the No. 1 turbo water hose sub-assembly.

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

    6. Remove the 2 nuts, compressor inlet elbow and gasket from the turbocharger sub-assembly.

  7. REMOVE NO. 1 TURBO INSULATOR


    1. A01DROC

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

  8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Remove the bolt and No. 1 exhaust manifold heat insulator from the exhaust manifold.

  9. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01DNMI

      Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.

  10. REMOVE TURBINE OUTLET ELBOW


    1. A01DQ9I

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

  11. REMOVE TURBOCHARGER STAY


    1. A01DQXY

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

  12. 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 from the turbocharger sub-assembly and cylinder block sub-assembly.

      Note

      Do not loosen the nut labeled A in the illustration.

  13. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


    1. A01DP60

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

    2. Remove the exhaust manifold with turbocharger and gasket.

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


    1. A01DS9D

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

  15. REMOVE COMPRESSOR ELBOW STAY


    1. A01DQ2A

      Remove the 2 bolts and compressor elbow stay.

  16. REMOVE WATER INLET


    1. A01DTAN

      Remove the 3 bolts and water inlet.

  17. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

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


    1. A01DN1Z

      Disconnect the 2 hoses.

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

  19. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01DTLB

      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.

  20. REMOVE TIMING GEAR COVER INSULATOR


    1. A01DTRI

      Remove the bolt and gear cover insulator.

  21. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DU2OE01

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

  22. REMOVE VANE PUMP ASSEMBLY


    1. A01DSPC

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

  23. 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.

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DTSI

      Remove the bolt and camshaft position sensor.

  25. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01DSL1

      Detach the clamp and remove the bolt and crankshaft position sensor.

  26. REMOVE NO. 1 TIMING BELT COVER


    1. A01DT7SE01

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

  27. 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.

  28. 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.

  29. 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 )

  30. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. A01DMQP

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  31. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  32. REMOVE INJECTION PIPE (w/ EGR System)

    Note


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

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


    1. A01DT2A

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

    2. A01DUQA

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

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  33. REMOVE AIR CONNECTOR STAY (w/ EGR System)


    1. A01DRSE

      Remove the 3 bolts and air connector stay.

  34. REMOVE EGR VALVE BRACKET (w/ EGR System)


    1. Remove the 2 nuts and EGR valve bracket.

  35. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)


    1. A01DRXH

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. A01DOAO

      Detach the wire harness clamp.

    3. A01DOLL

      Disconnect the 5 vacuum hoses.

    4. Remove the bolt and gas filter together with the gas filter bracket.

    5. A01DT6Y

      Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.

  36. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR System)


    1. A01DPM6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  37. REMOVE INTAKE AIR CONNECTOR (w/ EGR System)


    1. A01DOLG

      Remove the 3 bolts, intake air connector and 2 gaskets.

  38. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR System with EGR Cooler)


    1. A01DMW6

      Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.

    2. A01DOVN

      Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  39. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)


    1. A01DTMC

      Remove the 2 nuts and electric EGR control valve together with the No. 1 EGR pipe and gasket.

  40. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. A01DSG4E01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 2 bolts, electric EGR control valve and gasket.

  41. REMOVE EGR VALVE ADAPTER (w/ EGR System with EGR Cooler)


    1. A01DTMG

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

  42. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)


    1. A01DPOB

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.

  43. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A01DMLE

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  44. REMOVE INJECTION PIPE (w/o EGR System)

    Note


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

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


    1. A01DT2A

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

    2. A01DUQA

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

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  45. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A01DQ0T

      Remove the 3 bolts and air connector stay.

  46. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01DRU7

      Remove the 3 nuts.

    2. Remove the No. 2 intake air connector, No. 1 intake air connector and 2 gaskets.

  47. REMOVE INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01DM0X

      Remove the 3 bolts, intake air connector and gasket.

  48. REMOVE NO. 2 EGR HOLE COVER PLATE (w/o EGR System)


    1. A01DN9H

      Remove the 2 nut, gasket and No. 2 EGR hole cover plate.

  49. REMOVE WATER OUTLET


    1. A01DMCC

      Remove the 2 bolts, gasket and water outlet.

  50. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01DPXN

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

  51. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A01DRB4

      Remove the No. 1 intake manifold insulator.

  52. REMOVE GLOW PLUG ASSEMBLY


    1. A01DP9Q

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

  53. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A01DR0B

      Disconnect the No. 1 vacuum transmitting hose.

    2. A01DUDJ

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose assembly.

    3. A01DNW0

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    4. A01DSHRE01
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose assembly and No. 4 vacuum transmitting hose assembly.

    5. A01DUH7

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

  54. REMOVE INTAKE PIPE STAY


    1. A01DM2W

      Remove the bolt and intake pipe stay.

  55. REMOVE VACUUM CONTROL VALVE SET


    1. A01DPPT

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  56. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DO5J

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01DUTCE06
      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. 4 injection pipe.

  57. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNQTE01
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

    2. Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.

  58. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01DQZY

      Remove the 2 bolts and intake manifold insulator.

  59. REMOVE INTAKE MANIFOLD


    1. A01DNKHE01
      Text in Illustration
      *1 Sensor Wire

      Detach the sensor wire connector clamp from the intake manifold.

    2. A01DTMI

      Disconnect the vacuum hose from the intake manifold.

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

  60. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A01DSP3

      Remove the No. 2 intake manifold insulator.

  61. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DTQL

      Loosen the union nuts and remove the fuel inlet pipe.

  62. REMOVE COMMON RAIL ASSEMBLY


    1. A01DN95

      Remove the 2 bolts and common rail.

      Note

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

  63. REMOVE 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 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 supply pump.

      Note


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

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

  64. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A01DQ3E

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

  65. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DPTWE01

      Using SST, remove the oil filter.

      SST
      09228-07501

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


    1. A01DT40

      Disconnect the vacuum hose.

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

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


    1. A01DNUY

      Disconnect the vacuum hose.

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

  68. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. A01DRWS

      Remove the 13 bolts and oil cooler cover.

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


    1. A01DT5H

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

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


    1. A01DMUC

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

  71. REMOVE NO. 1 VACUUM PIPE


    1. A01DMA0

      Remove the bolt and No. 1 vacuum pipe.

  72. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A01DSTY

      Remove the No. 2 cylinder block insulator.

  73. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


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

      Remove the 8 bolts and 2 engine mounting brackets.