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 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. A004O9P

      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 FUEL HOSE PROTECTOR

    Click here

  36. REMOVE FUEL TUBE SUB-ASSEMBLY

    Click here

  37. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Click here

  38. REMOVE FUEL INJECTOR SEAL

    Click here

  39. REMOVE NO. 3 FUEL HOSE

    Click here

  40. 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.

  41. REMOVE FUEL HOSE PROTECTOR


    1. A004THZ

      Remove the fuel hose protector from the cylinder head.

  42. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A004TGH

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

  43. REMOVE NO. 1 TURBO OIL PIPE


    1. A004U8Y

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

  44. REMOVE VACUUM REGULATING VALVE ASSEMBLY

    Click here

  45. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  46. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  47. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR

    Click here

  48. REMOVE MANIFOLD STAY

    Click here

  49. REMOVE NO. 2 MANIFOLD STAY

    Click here

  50. REMOVE NO. 2 EXHAUST MANIFOLD STAY

    Click here

  51. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  52. REMOVE NO. 1 TURBO WATER HOSE (for Manual Transaxle)

    Click here

  53. REMOVE NO. 5 WATER BY-PASS HOSE (for Manual Transaxle)

    Click here

  54. REMOVE NO. 2 WATER BY-PASS HOSE (for Automatic Transaxle)

    Click here

  55. REMOVE EGR COOLER WITH PIPE ASSEMBLY

    Click here

  56. REMOVE TURBO OIL OUTLET PIPE

    Click here

  57. REMOVE NO. 1 TURBO INSULATOR

    Click here

  58. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  59. DISCONNECT NO. 3 WATER BY-PASS HOSE

    Click here

  60. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  61. REMOVE NO. 5 WATER BY-PASS PIPE (for Automatic Transaxle)

    Click here

  62. REMOVE NO. 2 TURBO OIL PIPE

    Click here

  63. REMOVE TURBOCHARGER STAY

    Click here

  64. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  65. REMOVE EXHAUST MANIFOLD


    1. A004OHB

      Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

  66. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A004T5V

      Remove the 3 bolts and bearing bracket.