ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

Note

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable some systems need to be initialized after the cable is reconnected Click here.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. REMOVE MAIN BATTERY

  8. REMOVE SUB-BATTERY

  9. REMOVE FRONT WHEEL

  10. REMOVE HOOD SUB-ASSEMBLY


    1. B001ZVW

      Remove the 2 hood stay bolts. Then disconnect the 2 hood supports.

      Note


      • Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing.

      • Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks.

      • Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed.

      • Remove the hood support while supporting the hood by hand.

    2. Remove the 4 bolts and hood.

  11. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. B001WYE

      Remove the 3 bolts and screw.

    2. Loosen the clip and remove the front fender splash shield LH.

  12. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Remove the 3 bolts and 2 screws.

    2. Loosen the clip and remove the front fender splash shield RH.

  13. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. B001Z4U

      Remove the 10 bolts and No. 1 engine under cover.

  14. REMOVE NO. 2 ENGINE UNDER COVER


    1. B001ZL5

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

  15. REMOVE OIL PAN PROTECTOR ASSEMBLY (for 1-piece Type)

    Click here

  16. REMOVE OIL PAN PROTECTOR ASSEMBLY LH (for 2-piece Type)

    Click here

  17. REMOVE OIL PAN PROTECTOR ASSEMBLY RH (for 2-piece Type)

    Click here

  18. DRAIN ENGINE COOLANT

    Click here

  19. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. B001Y63

      Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Install a new gasket and the oil pan drain plug.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  20. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  21. REMOVE NO. 3 ENGINE ROOM WIRE

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER FILTER ELEMENT

  24. REMOVE AIR CLEANER CASE


    1. B001ZQZ

      Using a clip remover, detach the wire harness clamp.

    2. Remove the 3 bolts and air cleaner case.

  25. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  26. REMOVE INTAKE AIR CONNECTOR

    Click here

  27. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  28. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  29. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  30. REMOVE VANE PUMP ASSEMBLY

    Click here

  31. DISCONNECT NO. 1 RADIATOR HOSE

  32. DISCONNECT NO. 2 RADIATOR HOSE

  33. REMOVE V-RIBBED BELT (w/ Viscous Heater)

    Click here

  34. REMOVE NO. 1 IDLER PULLEY (w/ Viscous Heater)

    Click here

  35. REMOVE NO. 3 IDLER PULLEY (w/ Viscous Heater)

    Click here

  36. REMOVE V-RIBBED BELT

    Click here

  37. REMOVE FRONT FENDER APRON SEAL FRONT RH


    1. B001YD2

      Remove the 3 clips and front fender apron seal front RH.

  38. REMOVE FRONT FENDER APRON SEAL REAR RH


    1. B001Z6M

      Remove the 4 clips and front fender apron seal rear RH.

  39. REMOVE FRONT FENDER APRON SEAL FRONT LH


    1. B001ZGV

      w/o KDSS:

      Remove the 4 clips and front fender apron seal front LH.

    2. B001ZFP

      w/ KDSS:

      Remove the 3 clips and front fender apron seal front LH.

  40. REMOVE FRONT FENDER APRON SEAL REAR LH


    1. B001WIE

      Remove the 4 clips and front fender apron seal rear LH.

  41. REMOVE OIL COOLER TUBE (for Automatic Transmission)

    Click here

  42. REMOVE FAN SHROUD WITH FAN

    Click here

  43. REMOVE FAN PULLEY

  44. REMOVE FRONT BUMPER WINCH COVER (w/ Winch)

    Click here

  45. REMOVE RADIATOR GRILLE

    Click here

  46. REMOVE FRONT BUMPER COVER

    Click here

  47. REMOVE TRANSMISSION OIL COOLER AIR DUCT (for Automatic Transmission)

    Click here

  48. DISCONNECT RADIATOR SIDE DEFLECTOR RH (for Manual Transmission)

    Click here

  49. DISCONNECT RADIATOR SIDE DEFLECTOR LH

    Click here

  50. REMOVE RADIATOR ASSEMBLY

    Click here

  51. DISCONNECT FRONT DIFFERENTIAL BREATHER TUBE

    B001YG6

  52. DISCONNECT FUEL TUBE


    1. w/ DPF:

      Disconnect the 2 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

    2. w/o DPF:

      Disconnect the 3 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

  53. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  54. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  55. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  56. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  57. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  58. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  59. DRAIN CLUTCH FLUID (for Manual Transmission)

  60. REMOVE CLUTCH HOSE (for Manual Transmission)

    Click here

  61. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  62. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  63. REMOVE NO. 1 GAS FILTER

    Click here

  64. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  65. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  66. REMOVE NO. 1 AIR HOSE

    Click here

  67. REMOVE NO. 3 AIR TUBE

    Click here

  68. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. B001WPY

      Remove the bolt and No. 1 air tube.

    2. Remove the O-ring.

  69. REMOVE NO. 2 AIR HOSE

    Click here

  70. REMOVE NO. 4 AIR TUBE

    Click here

  71. REMOVE NO. 2 AIR TUBE ASSEMBLY


    1. B001YAT

      Remove the bolt and No. 2 air tube.

    2. Remove the O-ring.

  72. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  73. REMOVE NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  74. REMOVE SUCTION HOSE SUB-ASSEMBLY

    Click here

  75. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. B001YAG

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 3 wire harness clamps.

    3. B001W6K

      Remove the 4 bolts and cooler compressor.

  76. REMOVE NO. 2 INTAKE AIR CONNECTOR PIPE


    1. B00200J

      w/ Intercooler:

      Disconnect the vacuum hose.

    2. B001ZV5

      Loosen the hose clamp, and remove the bolt and No. 2 intake air connector pipe.

  77. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  78. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  79. DISCONNECT FUEL HOSE

    Click here

  80. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  81. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  82. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B001WQBE01
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        w/ DPF:

        Disconnect the 7 connectors from the injector driver.

      2. w/o DPF:

        Disconnect the 4 connectors from the injector driver.

      3. Disconnect the 2 connectors and detach the wire harness holder from the relay block.

      4. Remove the bolt and disconnect the ground wire.

      5. Disconnect the wire harness from the wire harness clamp holder.

      6. B001X96E02

        Remove the bolt and disconnect the ground wire from the body panel.

      7. Using a clip remover, detach the ground wire clamp labeled A from the relay block side.

      8. Disconnect the wire harness from the wire harness clamp holder labeled B.

      9. B001WJV

        Remove the nut and detach the generator positive (+) cable holder from the relay block.

      10. Disconnect the generator positive (+) cable from the 2 clamps.

      11. B001VWP

        Disconnect the 2 connectors.

      12. Using a clip remover, detach the 3 wire harness clamps.

      13. B001YLVE02

        for RHD:

        Disconnect the 4 connectors and detach the wire harness tab labeled A from the relay block.

      14. for RHD:

        Disconnect the ECM connector.

      15. for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      16. Disconnect the 8 connectors.

        B001VWHE02
        Text in Illustration
        *A w/ DPF *B w/o DPF

      17. Remove the bolt and the engine wire harness bracket labeled B.

      18. Using a clip remover, detach the wire harness clamp labeled D.

      19. Remove the 2 bolts and disconnect the engine wire protector labeled A.

      20. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. B001Y7JE02

        for LHD:

        Disconnect the 4 connectors, and detach the wire harness holder from the relay block labeled A.

      2. for LHD:

        Disconnect the ECM connector.

      3. for LHD:

        Disconnect the wire harness from the wire harness clamp holder.

      4. Disconnect the 7 connectors.

        B001WECE02
        Text in Illustration
        *A w/ DPF *B w/o DPF

      5. Using a clip remover, detach the wire harness clamp.

      6. Remove the 3 bolts and disconnect the engine wire protector labeled A.

      7. Remove the bolt and the wire harness bracket labeled B.

      8. Remove the screw grommet, nut and the glow plug wire harness labeled C.

      9. B001YY6E04
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      10. for RHD:

        Remove the bolt and wire harness clamp holder.

      11. B001WJ3

        w/ Winch:

        Remove the bolt and disconnect the ground wire.

    3. Rear Side:


      1. B001XVJE02
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        Using a clip remover, detach the wire harness clamp.

      2. Remove the 2 bolts and 2 ground wires labeled C.

      3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

      4. w/ DPF:

        Disconnect the 3 connectors.

      5. w/o DPF:

        Disconnect the connector.

      6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

  83. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  84. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  85. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

    Click here

  86. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  87. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

    Click here

  88. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  89. REMOVE INJECTION PIPE LH

    Click here

  90. REMOVE NO. 2 FUEL PIPE (w/ DPF)

    Click here

  91. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  92. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  93. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  94. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  95. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  96. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

    Click here

  97. REMOVE INJECTION PIPE RH

    Click here

  98. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

  99. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    Click here

  100. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    Click here

  101. REMOVE CONNECTING WIRE (w/ DPF)

    Click here

  102. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  103. REMOVE INTAKE PIPE

    Click here

  104. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  105. REMOVE NO. 3 INTAKE MANIFOLD

    Click here

  106. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

    Click here

  107. REMOVE EGR PIPE INSULATOR (w/ EGR System)

    Click here

  108. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

    Click here

  109. REMOVE EGR COOLER INSULATOR (w/ EGR System)

    Click here

  110. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)

    Click here

  111. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)

    Click here

  112. DISCONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

    Click here

  113. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

    Click here

  114. REMOVE NO. 2 FUEL INJECTOR PROTECTOR (w/ DPF)

    Click here

  115. REMOVE NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)

    Click here

  116. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)

    Click here

  117. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  118. REMOVE NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  119. REMOVE NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  120. REMOVE FUEL HOSE BRACKET (w/ DPF)

    Click here

  121. REMOVE NO. 1 FUEL PIPE CLAMP (w/ DPF)

    Click here

  122. REMOVE NO. 1 INTAKE MANIFOLD

    Click here

  123. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

  124. INSTALL NO. 1 AND NO. 2 ENGINE HANGER


    1. Install the No. 1 and No. 2 engine hangers to the cylinder head RH and LH with the 4 bolts as shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      B001Z92E01

      Tech Tips

      No. 1 engine hanger 12281-51040
      No. 2 engine hanger 12282-51040
      Bolt 91671-80825
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *a RH
      *b LH

  125. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  126. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  127. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. B001WO3

      Remove the bolt and clutch release cylinder to flexible hose tube.

  128. REMOVE ENGINE ASSEMBLY


    1. B001XB6

      Attach an engine sling device and hang the engine with a chain block.

    2. Remove the 4 bolts from the engine mounting RH and LH side.

    3. Lift the engine out of the vehicle carefully.

      Note


      • Make sure the engine is clear of all wiring and hoses.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    4. Place the engine onto a work bench.

  129. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  130. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  131. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. B001W4S

      Using a wrench, hold the crankshaft.

      Note

      Do not turn the crankshaft counterclockwise.

      If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt Click here.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf }
      or more
    2. B001YG9

      Remove the 8 bolts.

    3. B001WW4E02

      Remove the rear drive plate spacer labeled A, drive plate and ring gear labeled B and rear crankshaft balancer weight labeled C.

  132. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. B001W4S

      Using a wrench, hold the crankshaft.

      Note

      Do not turn the crankshaft counterclockwise.

      If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt Click here.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf }
      or more
    2. B001WY3

      Remove the 8 bolts and flywheel.

  133. INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with bolts.

    2. Remove the 4 bolts and No. 1 and No. 2 engine hangers.

  134. REMOVE FRONT ENGINE MOUNTING INSULATOR RH

    Click here

  135. REMOVE FRONT ENGINE MOUNTING INSULATOR LH

    Click here