ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)

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  2. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

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  3. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE

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  4. REMOVE GENERATOR ASSEMBLY

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  5. REMOVE NO. 2 VENTILATION HOSE

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  6. REMOVE NO. 2 TURBO WATER HOSE

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  7. REMOVE BREATHER PLUG RH

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  8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  9. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE

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  10. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

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  11. REMOVE NO. 1 TURBOCHARGER STAY

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  12. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY

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  13. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH

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  14. REMOVE NO. 3 VENTILATION HOSE

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  15. REMOVE BREATHER PLUG LH

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  16. REMOVE NO. 2 TURBO WATER HOSE

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  17. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  18. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY

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  19. REMOVE FRONT WATER BY-PASS JOINT

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  20. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY

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  21. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE

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  22. REMOVE NO. 2 TURBOCHARGER STAY

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  23. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY

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  24. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

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  25. REMOVE VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

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

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  27. REMOVE WATER INLET

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  28. REMOVE THERMOSTAT

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  29. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)


    1. A01WZO6

      w/o Viscous Heater:

      Remove the 2 bolts and timing gear cover insulator.

    2. A01X1D2

      w/ Viscous Heater:

      Remove the timing gear cover insulator.

  30. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  31. REMOVE STARTER ASSEMBLY

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  32. REMOVE STARTER HOSE BRACKET

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  33. DISCONNECT INLET WATER HOSE

    A01X98U

  34. REMOVE DIESEL ENGINE COOLANT TEMPERATURE SENSOR

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  35. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET


    1. A01XAWD

      Remove the 2 bolts and No. 2 intercooler support bracket.

  36. REMOVE WATER OUTLET


    1. A01X7QU

      Remove the 2 bolts and gasket and disconnect the water outlet from the No. 2 water hose joint.

  37. REMOVE WATER OUTLET PIPE


    1. A01X9DM

      Remove the 4 bolts, water outlet pipe and 2 gaskets.

  38. SEPARATE NO. 1 AND NO. 2 WATER OUTLET PIPES AND WATER BY-PASS OUTLET


    1. A01X9RT

      Remove the 2 bolts and No. 1 water outlet pipe from the No. 2 water outlet pipe.

    2. A01XAVR

      Disconnect the No. 2 water outlet pipe from the No. 1 water hose joint.

    3. A01X53Q

      Disconnect the water by-pass outlet from the No. 1 water hose joint.

  39. REMOVE CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. A01X253

      Remove the 2 bolts and clutch flexible hose bracket.

  40. REMOVE NO. 1 GLOW PLUG CONNECTOR

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  41. REMOVE GLOW PLUG ASSEMBLY

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  42. REMOVE FUEL PUMP MOTOR WIRE


    1. A01X1TU

      Disconnect the 2 connectors and remove the bolt and fuel pump motor wire.

  43. REMOVE NO. 2 IDLER PULLEY (w/ Viscous Heater)

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  44. REMOVE NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

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  45. REMOVE FAN BRACKET SUB-ASSEMBLY

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

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

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


    1. A01XBS3

      w/ Intercooler:

      Remove the 3 bolts and cylinder head cover silencer RH.

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


    1. A01X8LF

      w/ Intercooler:

      Remove the 3 bolts and cylinder head cover silencer LH.

  50. REMOVE REAR CYLINDER HEAD PLATE RH (w/o EGR System)


    1. A01X8IS

      Remove the 2 bolts, rear cylinder head plate RH and gasket.

  51. REMOVE REAR CYLINDER HEAD PLATE LH (w/o EGR System)


    1. A01X5ZW

      Remove the 2 bolts, rear cylinder head plate LH and gasket.

  52. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET


    1. A01X8E4

      Remove the 2 bolts and No. 1 intake air connector bracket.

  53. REMOVE AIR TUBE SUPPORT


    1. A01XA5Z

      Remove the 2 bolts and air tube support.

  54. REMOVE NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01XAC5

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  55. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01X5B6

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 4 vacuum transmitting pipe.

  56. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01WZX3

      Remove the 4 bolts and engine mounting bracket RH.

  57. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    A01X7IV

  58. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A01X5C1

      Detach the 2 wire harness clamps.

    2. A01WZ16

      Remove the bolt and No. 2 intake air connector bracket.

  59. REMOVE TURBOCHARGER WIRE


    1. A01X7CC

      Detach the 3 wire harness clamps.

    2. Remove the 2 bolts and turbocharger wire.

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


    1. A01WZTA

      w/ Intercooler:

      Disconnect the vacuum hose.

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

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


    1. A01WZ5U

      Remove the union bolt, 2 bolts, No. 2 water by-pass pipe and gasket.

  62. REMOVE ENGINE MOUNTING BRACKET LH


    1. A01XBUR

      Remove the 4 bolts and engine mounting bracket LH.

  63. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    A01X0UV

  64. REMOVE OIL TANK BRACKET


    1. A01X6UQ

      Remove the bolt and oil tank bracket.

  65. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET


    1. A01X2A2

      Remove the 2 bolts and No. 1 intercooler support bracket.

  66. REMOVE NO. 3 ENGINE HANGER


    1. A01X80C

      Remove the 2 bolts and No. 3 engine hanger.

  67. REMOVE OIL FILTER BRACKET DRAIN COCK ASSEMBLY


    1. A01X6YH

      Remove the oil filter drain cock plug.

    2. A01X6ON

      Remove the oil filter drain cock body.

      Tech Tips

      If the drain cock is deformed or clogged, replace or repair it.

  68. REMOVE OIL PRESSURE REGULATOR ASSEMBLY


    1. A01WZRE

      Using a 26 mm wrench, remove the oil pressure regulator and gasket.

    2. Remove the O-ring from the oil pressure regulator body.

    3. Hold the oil pressure regulator body in a vise between aluminum plates.

      Note

      Be careful not to damage the oil pressure regulator body.

    4. A01X6BLE01

      Using a 10 mm hexagon wrench, remove the oil pump relief valve plug labeled A and gasket.

      CAUTION:

      When removing the plug, be careful as the spring will be jumped out.

    5. Remove the 2 springs labeled B.

    6. Remove the oil pump relief valve labeled C.

  69. REMOVE STIFFENER INSULATOR RH (w/ Intercooler)

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  70. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01X166E04
      Text in Illustration
      *1 Timing Mark

      Align the timing mark of the crankshaft pulley and the chain cover and compressor bracket.

  71. REMOVE COMPRESSOR BRACKET


    1. A01X6WC

      Remove the bolt and compressor bracket.

  72. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (w/ DPF)

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  73. REMOVE FUEL INJECTOR SEAL (w/ DPF)

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  74. REPLACE FLYWHEEL RING GEAR

    CAUTION:

    A01X877E02

    When torching the flywheel:


    • Wear protective gloves.

    • Be careful as the flywheel is hot.

    Tech Tips

    If the flywheel ring gear is deformed or the gear teeth are damaged, replace it.


    1. Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

    2. Install 8 10 mm x 1.25 pitch bolts with a length of 70 mm or more to the flywheel.

    3. Uniformly tighten the 8 bolts in the order shown in the illustration.

    4. Remove the ring gear from the flywheel.

    5. A01X9A6E02
      Text in Illustration
      *a No Clearance

      Using a torch, heat a new ring gear evenly to approximately 200°C (392°F).

      Note

      Be careful not to overheat the ring gear.

    6. Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.

      Note


      • Make sure to press in the ring gear until the ring gear contacts the flywheel, as shown in A in the illustration.

      • After installing, allow the ring gear to cool before handling.

  75. REPLACE FLYWHEEL STRAIGHT PIN

    Tech Tips

    It is not necessary to remove the straight pin unless it is being replaced.


    1. Replace the flywheel straight pin.