ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. REMOVE COMPRESSOR STAY


    1. A004SHJ

      Remove the compressor stay from the cylinder block.

  2. REMOVE GENERATOR ASSEMBLY


    1. A004SE8

      Remove the 3 bolts and generator.

  3. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A004RY0

      Remove the bolt, plate and No. 2 idler pulley.

  4. REMOVE IDLER PULLEY COVER PLATE


    1. A004RC5

      Using a screwdriver, remove the idler pulley cover plate.

  5. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A004NV5

      Remove the bolt and No. 1 idler pulley.

  6. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A004SC0

      Remove the bolt, No. 4 water by-pass pipe and O-ring.

  7. REMOVE ENGINE MOUNTING BRACKET


    1. A004NIC

      Remove the 4 bolts, 2 nuts and engine mounting bracket.

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A004OOO

      Remove the 3 bolts and V-ribbed belt tensioner.

      Note

      As the bolt heads are not as thick as typical bolts, be careful not to damage them during removal.

  9. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  11. REMOVE NO. 7 WATER BY-PASS HOSE

    Click here

  12. DISCONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  13. REMOVE EGR VALVE BRACKET

    Click here

  14. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  19. REMOVE NO. 4 FUEL HOSE

    Click here

  20. REMOVE COMMON RAIL ASSEMBLY

    Click here

  21. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  22. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  23. REMOVE NO. 1 GAS FILTER

    Click here

  24. REMOVE GAS FILTER BRACKET

    Click here

  25. REMOVE ENGINE COVER BRACKET

    Click here

  26. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

  27. REMOVE INTAKE MANIFOLD

    Click here

  28. REMOVE GLOW PLUG ASSEMBLY


    1. A004OKU

      Remove the 4 grommets.

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

    3. Using a 10 mm deep socket wrench, remove the 4 glow plugs.

  29. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  30. REMOVE WATER BY-PASS HOSE

    Click here

  31. REMOVE NO. 6 WATER BY-PASS HOSE

    Click here

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    Click here

  33. REMOVE NO. 4 WATER BY-PASS HOSE

    Click here

  34. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  35. REMOVE NO. 2 FUEL PIPE (for CCo)

    Click here

  36. REMOVE FUEL HOSE PROTECTOR (for DPF)

    Click here

  37. REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)

    Click here

  38. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)

    Click here

  39. REMOVE FUEL INJECTOR SEAL (for DPF)

    Click here

  40. REMOVE NO. 3 FUEL HOSE

    Click here

  41. REMOVE SUPPLY PUMP ASSEMBLY


    1. A004OIL

      Remove the 2 bolts, supply pump and No. 1 supply pump drive coupling.

    2. Remove the O-ring from the supply pump.

  42. REMOVE FUEL HOSE PROTECTOR


    1. A004THZ

      Remove the fuel hose protector from the cylinder head.

  43. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A004TGH

      Remove the 2 bolts and No. 3 water by-pass pipe.

  44. REMOVE NO. 1 TURBO OIL PIPE


    1. A004U8Y

      Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.

  45. REMOVE VACUUM REGULATING VALVE ASSEMBLY (for CCo)

    Click here

  46. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  47. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  48. REMOVE NO. 1 WIRE HARNESS CLAMP BRACKET (for DPF)

    Click here

  49. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR (for CCo)

    Click here

  50. REMOVE NO. 4 MANIFOLD CONVERTER INSULATOR (for DPF)

    Click here

  51. REMOVE MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY (for DPF)

    Click here

  52. REMOVE MANIFOLD STAY (for CCo)

    Click here

  53. REMOVE MANIFOLD STAY (for DPF)

    Click here

  54. REMOVE NO. 2 MANIFOLD STAY (for CCo)

    Click here

  55. REMOVE NO. 2 MANIFOLD STAY (for DPF)

    Click here

  56. REMOVE NO. 2 EXHAUST MANIFOLD STAY (for CCo)

    Click here

  57. REMOVE NO. 2 EXHAUST MANIFOLD STAY (for DPF)

    Click here

  58. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for CCo)

    Click here

  59. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for DPF)

    Click here

  60. REMOVE NO. 2 WATER BY-PASS HOSE

    Click here

  61. REMOVE EGR COOLER WITH PIPE ASSEMBLY

    Click here

  62. REMOVE TURBOCHARGER SUB-ASSEMBLY (for CCo)

    Click here

  63. REMOVE TURBOCHARGER SUB-ASSEMBLY (for DPF)

    Click here

  64. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A004T5V

      Remove the 3 bolts and bearing bracket.