ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE GENERATOR ASSEMBLY


    1. A01XGK5

      Remove the 2 bolts and generator.

  2. REMOVE GENERATOR BRACKET


    1. A01XJ44

      Remove the bolt and generator bracket.

  3. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01XF4N

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  4. REMOVE VENTILATION PIPE

    Click here

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  6. REMOVE COMPRESSOR INLET ELBOW

    Click here

  7. REMOVE NO. 1 TURBO INSULATOR

    Click here

  8. REMOVE NO. 1 EXHAUST MANIFOLD HEATINSULATOR

    Click here

  9. DISCONNECT NO. 1 TURBO WATER HOSE

    Click here

  10. REMOVE TURBINE OUTLET ELBOW

    Click here

  11. REMOVE TURBOCHARGER STAY

    Click here

  12. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  13. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  14. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01XFHV

      Remove the 4 bolts and No. 2 cylinder head cover.

  15. REMOVE COMPRESSOR ELBOW STAY


    1. A01XLX0

      Remove the 2 bolts and compressor elbow stay.

  16. REMOVE WATER INLET


    1. A01XCJZ

      Remove the 3 bolts and water inlet.

  17. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

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


    1. A01XITF

      Disconnect the 2 hoses.

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

  19. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01XE8U

      Remove the 4 bolts and engine oil level sensor.

    2. Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Tech Tips

      Remove only the outer part of the gasket.

  20. REMOVE TIMING GEAR COVER INSULATOR


    1. A01XJJ9

      Remove the bolt and gear cover insulator.

  21. REMOVE VACUUM PUMP ASSEMBLY


    1. A01XCVWE02

      Remove the 2 nuts, vacuum pump and 2 O-rings.

  22. REMOVE VANE PUMP ASSEMBLY


    1. A01XDG2

      Remove the 2 nuts, vane pump and O-ring.

  23. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. A01XIY3

      Remove the bolt and camshaft position sensor.

  25. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01XEDT

      Detach the clamp and remove the bolt and crankshaft position sensor.

  26. REMOVE NO. 1 TIMING BELT COVER

    Click here

  27. REMOVE TIMING BELT

    Click here

  28. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  29. REMOVE CRANKSHAFT PULLEY

    Click here

  30. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  31. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  32. REMOVE INJECTION PIPE (w/ EGR System)

    Click here

  33. REMOVE AIR CONNECTOR STAY (w/ EGR System)

    Click here

  34. REMOVE EGR VALVE BRACKET (w/ EGR System)

    Click here

  35. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)

    Click here

  36. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR System)

    Click here

  37. REMOVE INTAKE AIR CONNECTOR (w/ EGR System)

    Click here

  38. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITHNO. 2 EGR VALVE AND EGR COOLER (w/ EGR System with EGR Cooler)

    Click here

  39. REMOVE ELECTRIC EGR CONTROL VALVEASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  40. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)

    Click here

  41. REMOVE EGR VALVE ADAPTER (w/ EGR System with EGR Cooler)

    Click here

  42. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  43. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A01XGYI

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  44. REMOVE INJECTION PIPE (w/o EGR System)

    Click here

  45. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A01XJ55

      Remove the 3 bolts and air connector stay.

  46. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01XG7Q

      Remove the 3 nuts.

    2. Remove the No. 2 intake air connector, No. 1 intake air connector and 2 gaskets.

  47. REMOVE INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01XEIV

      Remove the 3 bolts, intake air connector and gasket.

  48. REMOVE NO. 2 EGR HOLE COVER PLATE (w/o EGR System)


    1. A01XD3X

      Remove the 2 nut, gasket and No. 2 EGR hole cover plate.

  49. REMOVE WATER OUTLET


    1. A01XISN

      Remove the 2 bolts, gasket and water outlet.

  50. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01XIOX

      Remove the 4 screw grommets, 4 nuts and No. 1 glow plug connector.

  51. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A01XM62

      Remove the No. 1 intake manifold insulator.

  52. REMOVE GLOW PLUG ASSEMBLY


    1. A01XEJ9

      Using a 12 mm deep socket wrench, remove the 4 glow plugs.

  53. REMOVE MANIFOLD STAY WITH VACUUMSWITCHING VALVE


    1. B001FXJ

      Disconnect the No. 1 vacuum transmitting hose.

    2. B001GI7

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose assembly.

    3. B001GEM

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    4. A01XGWRE01
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose assembly and No. 4 vacuum transmitting hose assembly.

    5. B001EGN

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  54. REMOVE INTAKE PIPE STAY

    Click here

  55. REMOVE VACUUM CONTROL VALVE SET

    Click here

  56. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  57. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  58. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  59. REMOVE INTAKE MANIFOLD

    Click here

  60. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A01XMO9

      Remove the No. 2 intake manifold insulator.

  61. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01XF9C

      Loosen the union nuts and remove the fuel inlet pipe.

  62. REMOVE COMMON RAIL ASSEMBLY


    1. A01XI0T

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.

  63. REMOVE SUPPLY PUMP ASSEMBLY


    1. B001DLA

      Remove the 4 bolts indicated by the arrows in the illustration.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    3. A01XE3CE10

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    4. A01XM2X

      Loosen the 2 nuts.

    5. A01XCCSE07

      Using SST, disconnect the supply pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. Remove the 2 nuts and supply pump.

      Note


      • Do not hold or carry the fuel supply pump by holding the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

  64. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A01XG5I

      Remove the 2 bolts and No. 1 injection pump protector.

  65. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

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


    1. A01XINM

      Disconnect the vacuum hose.

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

  67. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01XJ42

      Disconnect the vacuum hose.

    2. Remove the 2 nuts and No. 2 vacuum transmitting pipe.

  68. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. A01XHXJ

      Remove the 13 bolts and oil cooler cover.

  69. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01XI7T

      Remove the bolt, nut and No. 1 vacuum transmitting pipe.

  70. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. A01XETB

      Remove the 4 bolts and No. 1 oil pan cover.

  71. REMOVE NO. 1 VACUUM PIPE


    1. A01XGXI

      Remove the bolt and No. 1 vacuum pipe.

  72. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A01XJPX

      Remove the No. 2 cylinder block insulator.

  73. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01XGRFE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Remove the 8 bolts and 2 engine mounting brackets.