ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

Note


  • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

  • When working on the fuel circuit, protect the generator assembly against dirt contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

  • A004OHTE01

    After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

    SST
    PZ4TB-04941-79

PROCEDURE


  1. REMOVE ENGINE COVER

    Click here

  2. DISCONNECT ENGINE WIRE

  3. REMOVE FAN AND GENERATOR V BELT

    Click here

  4. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  5. REMOVE GENERATOR ASSEMBLY

    Click here

  6. REMOVE IDLER PULLEY ASSEMBLY


    1. A004T59

      Using a T50 "TORX" socket wrench, loosen the bolt to remove the idler pulley assembly.

      Tech Tips

      Bolt cannot be removed from the idler pulley assembly.

  7. REMOVE ENGINE MOUNTING BRACKET


    1. A004PRG

      Using an E12 "TORX" socket wrench, remove the 3 bolts and engine mounting bracket.

    2. Remove the stud bolt from the engine mounting bracket.

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A004TS6

      Remove the 2 bolts and V-ribbed belt tensioner assembly.

  9. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  10. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  11. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

    Click here

  12. REMOVE NO. 2 VACUUM HOSE ASSEMBLY


    1. A004NHT

      Remove the bolt, nut and No. 2 vacuum hose assembly from the No. 2 engine hanger.

  13. REMOVE NO. 1 VACUUM PIPE

    Click here

  14. REMOVE INTAKE MANIFOLD

    Click here

  15. REMOVE FUEL FEED PIPE SUB-ASSEMBLY


    1. A004RTU

      Disconnect the nozzle leakage pipe assembly from the fuel feed pipe sub-assembly.

    2. A004UEH

      Loosen the 2 clamps and disconnect the 2 fuel hoses from the fuel supply pump assembly.

    3. Disconnect the fuel return tube from the common rail assembly.

      Click here

    4. Detach the fuel hose clamp.

    5. Remove the 2 bolts and fuel feed pipe sub-assembly.

  16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  17. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  18. REMOVE TURBO OIL OUTLET PIPE

    Click here

  19. DISCONNECT NO. 1 TURBO OIL PIPE

    Click here

  20. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  21. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

    Click here

  22. REMOVE EXHAUST MANIFOLD

    Click here

  23. REMOVE NO. 1 TURBO OIL PIPE


    1. A004PYF

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

  24. REMOVE NO. 2 TURBO INSULATOR


    1. A004P4V

      Remove the 3 bolts and No. 2 turbo insulator.

  25. REMOVE TURBOCHARGER STAY


    1. A004TWA

      Remove the 2 bolts and turbocharger stay.

  26. REMOVE EGR VALVE BRACKET


    1. A004Q66

      Remove the 2 bolts and EGR valve bracket from the cylinder head sub-assembly.

  27. REMOVE NO. 2 ENGINE HANGER


    1. A004OAU

      Remove the 2 bolts and No. 2 engine hanger from the cylinder head sub-assembly.

  28. REMOVE NO. 1 ENGINE HANGER


    1. A004R32

      Remove the bolt and No. 1 engine hanger from the cylinder head sub-assembly.

  29. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  30. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  31. REMOVE COMMON RAIL ASSEMBLY

    Click here

  32. REMOVE GLOW PLUG ASSEMBLY

    Click here

  33. REMOVE EGR BYPASS VALVE SWITCHING VALVE ASSEMBLY

    Click here

  34. REMOVE VACUUM CONTROL VALVE BRACKET

    Click here

  35. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A004STN

      Using an T50 "TORX" socket wrench, remove the 3 bolts and drive shaft bearing bracket.