ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A000QYJ

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

  2. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A000OKY

      Slide the clip and disconnect the water by-pass hose from the No. 2 water by-pass pipe.

    2. Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.

  3. REMOVE WATER BY-PASS PIPE (w/o EGR System)


    1. A000SBEE03
      Text in Illustration
      *1 No. 5 Water By-pass Hose
      *2 No. 6 Water By-pass Hose

      Slide the 2 clips and disconnect the No. 5 water by-pass hose and No. 6 water by-pass hose from the water by-pass pipe.

    2. A000PTS

      Remove the bolt, nut and water by-pass pipe from the cylinder head sub-assembly.

  4. DISCONNECT EGR VALVE BRACKET (w/ EGR System)

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  5. REMOVE EGR COOLER ASSEMBLY (w/ EGR System)

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  6. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A000N2Q

      Remove the 2 bolts and No. 2 water by-pass pipe from the cylinder head sub-assembly.

  7. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A000SY0E03

      Slide the clip and disconnect the No. 13 water by-pass hose from the water outlet sub-assembly.

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

  8. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A000SPH

      Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.

  9. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A000RZB

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  10. REMOVE IGNITION COIL ASSEMBLY

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  11. REMOVE ENGINE COVER JOINT


    1. A000SQE

      Remove the 3 engine cover joints.

  12. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A000NA3

      Remove the 9 bolts and 7 wire harness clamp brackets.

  13. REMOVE ENGINE WATER PUMP ASSEMBLY

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  14. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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  15. REMOVE NO. 5 WATER BY-PASS PIPE


    1. A000SASE03
      Text in Illustration
      *1 No. 11 Water By-pass Hose
      *2 No. 5 Water By-pass Pipe

      Slide the clip and disconnect the No. 11 water by-pass hose from the water outlet sub-assembly.

    2. Remove the bolt, 2 nuts and No. 5 water by-pass pipe from the water inlet housing.

    3. Remove the gasket from the water inlet housing.

  16. REMOVE WATER INLET HOUSING


    1. A000PGH

      Remove the 2 bolts, nut and water inlet housing from the cylinder block sub-assembly.

    2. Remove the gasket from the water inlet housing.

      Note

      If a stud bolt is deformed or its threads are damaged, replace it.

  17. REMOVE NO. 1 FUEL PIPE

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  18. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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  19. REMOVE FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  20. REMOVE FUEL DELIVERY PIPE

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  21. REMOVE FUEL INJECTOR ASSEMBLY

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  22. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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  23. REMOVE FUEL INJECTOR SET

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  24. REMOVE FUEL INJECTOR SEAL

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  25. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  26. REMOVE WATER OUTLET SUB-ASSEMBLY

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