ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge valve or fuel pressure sensor, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. REMOVE NO. 3 ENGINE COVER BRACKET

    Click here

  2. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  3. REMOVE ENGINE WIRE

  4. REMOVE AIR TUBE ASSEMBLY

    Click here

  5. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  6. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  7. REMOVE DIFFERENTIAL PRESSURE SENSOR

    Click here

  8. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    Click here

  9. REMOVE NO. 1 VACUUM PIPE

    Click here

  10. REMOVE NO. 2 VACUUM PIPE

    Click here

  11. REMOVE PIPE CLAMP

    Click here

  12. REMOVE ENGINE COVER BRACKET


    1. B001G07

      Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

  13. REMOVE GAS FILTER

    Click here

  14. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  15. REMOVE EGR VALVE BRACKET

    Click here

  16. REMOVE NO. 2 EGR PIPE

    Click here

  17. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE CONNECTING WIRE


    1. B001DFH

      Disconnect the connector from the common rail assembly.

    2. Detach the 2 clamps and remove the connecting wire from the hose bracket.

  19. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B001HYF

      Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 gaskets from the exhaust manifold and electric EGR control valve assembly.

    3. B001H0Z

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  20. REMOVE VACUUM CONTROL VALVE SET

    Click here

  21. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B001IA2E01
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
      *3 Water Hose
      *4 No. 11 Water By-pass Hose

      Slide the clamp and disconnect the No. 6 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    2. Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    4. for Cold Area Specification Vehicles:

      Detach the clamp and disconnect the No. 11 water by-pass hose from the No. 2 fuel pipe.

    5. Remove the 2 bolts and No. 4 water by-pass pipe sub-assembly from the intake manifold.

  22. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  24. REMOVE NO. 2 FUEL PIPE


    1. B001CL8

      Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

    2. Remove the bolt and No. 2 fuel pipe from the manifold stay.

  25. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  26. REMOVE MANIFOLD STAY

    Click here

  27. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  28. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  29. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  30. REMOVE NO. 2 FUEL HOSE

    Click here

  31. REMOVE NO. 1 FUEL HOSE

    Click here

  32. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  33. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  34. REMOVE INTAKE MANIFOLD

    Click here

  35. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  36. REMOVE NO. 1 FUEL PIPE

    Click here

  37. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  38. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B001FMV

      for LHD:

      Remove the 3 bolts and 3 wiring harness clamp brackets from the cylinder head cover sub-assembly.

    2. B001F0R

      for RHD:

      Remove the 2 bolts and 2 wiring harness clamp brackets from the cylinder head cover sub-assembly.

  39. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  40. REMOVE COMMON RAIL ASSEMBLY

    Click here

  41. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  42. REMOVE GLOW PLUG ASSEMBLY

    Click here

  43. REMOVE HOSE BRACKET


    1. B001E6L

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

  44. REMOVE NO. 3 FUEL PIPE

    Click here

  45. REMOVE FUEL FILTER ASSEMBLY


    1. B001H6A

      Remove the 2 nuts and fuel filter assembly from the cylinder block sub-assembly.

  46. REMOVE NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B001D33

      Remove the 3 bolts, No. 5 water by-pass pipe sub-assembly and gasket from the cylinder block sub-assembly.

  47. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B001HCW

      Remove the 4 bolts and No. 1 compressor mounting bracket from the cylinder block sub-assembly, timing chain case assembly and timing chain cover sub-assembly.

  48. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  49. REMOVE PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  50. REMOVE PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  51. REMOVE NO. 5 WATER BY-PASS HOSE


    1. B001CV0

      Slide the 2 clamps and disconnect the No. 5 water by-pass hose from the No. 1 injector holder and water outlet sub-assembly.

    2. Detach the clamp and remove the No. 5 water by-pass hose from the No. 1 water hose clamp bracket.

  52. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B001HSQ

      Slide the clamp and disconnect the No. 4 water by-pass hose from the No. 1 injector holder.

  53. REMOVE NO. 1 INJECTOR HOLDER

    Click here

  54. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  55. REMOVE AIR FUEL RATIO SENSOR

    Click here

  56. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  57. REMOVE NO. 1 TURBO INSULATOR

    Click here

  58. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

    Click here

  59. REMOVE EXHAUST PIPE SUPPORT STAY

    Click here

  60. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  61. REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. B001H35

      Disconnect the No. 3 vacuum transmitting hose sub-assembly from the front engine mounting insulator RH.

    2. Remove the nut and front engine mounting insulator RH from the front No. 1 engine mounting bracket RH.

  62. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  63. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B001FAAE01
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

      Remove the 3 bolts, No. 1 water by-pass pipe and gasket from the timing chain cover sub-assembly.

  64. DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  65. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. B001FF8

      Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly from the cylinder block sub-assembly and timing chain cover sub-assembly.

  66. REMOVE TURBOCHARGER STAY

    B001G8Z

    1. Remove the 3 bolts, nut and the turbocharger stay.

  67. REMOVE TURBO OIL OUTLET PIPE

    Click here

  68. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  69. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B001HQ2

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the exhaust manifold.

  70. REMOVE EXHAUST MANIFOLD

    Click here

  71. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

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


    1. B001DLM

      Slide the clamp and disconnect the No. 3 water by-pass hose from the water outlet sub-assembly.

    2. Remove the 2 bolts and No. 2 water by-pass pipe sub-assembly from the engine water pump assembly and water inlet.

  73. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B001EA7E01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 4 bolts, 2 nuts and water outlet sub-assembly from the timing chain cover sub-assembly.

    2. Remove the gasket from the timing chain cover sub-assembly.

  74. REMOVE WATER INLET

    Click here

  75. REMOVE THERMOSTAT

    Click here

  76. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  77. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  78. REMOVE VACUUM PUMP ASSEMBLY


    1. B001FRC

      Disconnect the No. 1 vacuum transmitting hose sub-assembly from the vacuum pump assembly.

    2. Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.

    3. Remove the 2 O-rings from the vacuum pump assembly.

  79. REMOVE VACUUM SWITCHING VALVE SUB-ASSEMBLY (for Engine Mounting)

    Click here

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


    1. B001EGJ

      Disconnect the No. 2 vacuum transmitting hose sub-assembly from the No. 3 vacuum transmitting pipe sub-assembly.

    2. Remove the 3 bolts and No. 1 vacuum transmitting pipe sub-assembly from the cylinder head sub-assembly.

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


    1. B001CF7

      Remove the 2 bolts and No. 2 vacuum transmitting pipe sub-assembly from the cylinder block sub-assembly and oil pan sub-assembly.

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


    1. B001EE7

      Disconnect the No. 4 vacuum transmitting hose sub-assembly from the No. 3 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe sub-assembly from the cylinder head sub-assembly and cylinder block sub-assembly.

  83. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. B001IIW

      Remove the bolt and No. 4 vacuum transmitting pipe sub-assembly from the cylinder block sub-assembly.

  84. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. B001H9M

      Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-assembly.

  85. REMOVE VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  86. REMOVE CRANKSHAFT PULLEY COVER

    Click here

  87. REMOVE CRANKSHAFT PULLEY

    Click here

  88. REMOVE NO. 1 WATER HOSE CLAMP BRACKET


    1. B001DQQ

      Remove the bolt and No. 1 water hose clamp bracket from the timing chain case assembly.