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 engine 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.


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    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. B0018UV

      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 sub-assembly by hand.

    2. Remove the 4 bolts and hood sub-assembly.

  11. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. B0019AS

      Remove the 3 bolts and 2 screws.

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

  12. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. B001ALT

      Remove the 3 bolts and 2 screws.

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

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


    1. B001B0V

      Remove the 10 bolts and No. 1 engine under cover sub-assembly.

  14. REMOVE NO. 2 ENGINE UNDER COVER


    1. B001AY9

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

  15. REMOVE OIL PAN PROTECTOR ASSEMBLY (w/o DPF)

    Click here

  16. REMOVE OIL PAN PROTECTOR ASSEMBLY LH (w/ DPF)

    Click here

  17. REMOVE OIL PAN PROTECTOR ASSEMBLY RH (w/ DPF)

    Click here

  18. DRAIN ENGINE COOLANT

    Click here

  19. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. B001AV7

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

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

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

  20. REMOVE INTERCOOLER ASSEMBLY

    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. B0018WC

      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. B001AQ7

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

  38. REMOVE FRONT FENDER APRON SEAL REAR RH


    1. B00182X

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

  39. REMOVE FRONT FENDER APRON SEAL FRONT LH


    1. B001AYL

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

  40. REMOVE FRONT FENDER APRON SEAL REAR LH


    1. B0018HM

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

  41. REMOVE OIL COOLER TUBE

    Click here

  42. REMOVE FAN SHROUD WITH FAN

    Click here

  43. REMOVE FAN PULLEY

  44. REMOVE FRONT BUMPER COVER

    Click here

  45. REMOVE TRANSMISSION OIL COOLER AIR DUCT

    Click here

  46. DISCONNECT RADIATOR SIDE DEFLECTOR LH

    Click here

  47. REMOVE RADIATOR ASSEMBLY

    Click here

  48. DISCONNECT FRONT DIFFERENTIAL BREATHER TUBE

    B00190T

  49. DISCONNECT FUEL TUBE


    1. w/ DPF:

      Disconnect the No. 1 fuel main tube and fuel return tube from No. 1 fuel tube clamp and No. 3 fuel tube clamp.

    2. w/o DPF:

      Disconnect the No. 1 fuel main tube and 2 fuel return tube from the No. 1 fuel tube clamp and No. 3 fuel tube clamp.

  50. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  51. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  52. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  53. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  54. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  55. REMOVE NO. 1 GAS FILTER

    Click here

  56. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  57. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  58. REMOVE NO. 1 AIR HOSE

    Click here

  59. REMOVE NO. 3 AIR TUBE

    Click here

  60. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. B001B4X

      Remove the bolt and No. 1 air tube assembly.

    2. Remove the O-ring from the No. 1 air tube assembly.

  61. REMOVE NO. 2 AIR HOSE

    Click here

  62. REMOVE NO. 4 AIR TUBE

    Click here

  63. REMOVE NO. 2 AIR TUBE ASSEMBLY


    1. B00188B

      Remove the bolt and No. 2 air tube assembly.

    2. Remove the O-ring from the No. 2 air tube assembly.

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

    Click here

  65. REMOVE NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  66. REMOVE SUCTION HOSE SUB-ASSEMBLY

    Click here

  67. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. B0019OH

      Disconnect the 4 connectors.

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

    3. B001AL5

      Remove the 4 bolts and cooler compressor assembly.

  68. REMOVE NO. 2 INTAKE AIR CONNECTOR PIPE


    1. B0018VJ

      Disconnect the vacuum hose.

    2. B0019WS

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

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

    Click here

  70. REMOVE AIR CLEANER PIPE

    Click here

  71. DISCONNECT FUEL HOSE

    Click here

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

    Click here

  73. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  74. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B001989E01
        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 2 connectors from the injector driver.

      3. Disconnect the 4 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. B0019FEE02

        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. B001A3I

        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. B001AGS

        Disconnect the 2 connectors.

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

      13. B0018E3E02

        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.

        B001837E02
        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. B00183ZE02

        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.

        B001915E02
        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. B001AQQE04
        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.

    3. Rear Side:


      1. B00192NE03
        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.

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

    Click here

  76. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  81. REMOVE INJECTION PIPE SUB-ASSEMBLY LH

    Click here

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

    Click here

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

    Click here

  84. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

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

    Click here

  86. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  87. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

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

    Click here

  89. REMOVE INJECTION PIPE SUB-ASSEMBLY RH

    Click here

  90. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

  91. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  92. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  93. REMOVE CONNECTING WIRE (w/ DPF)

    Click here

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

    Click here

  95. REMOVE INTAKE PIPE

    Click here

  96. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  97. REMOVE NO. 3 INTAKE MANIFOLD

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  109. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

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

    Click here

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

    Click here

  112. REMOVE FUEL HOSE BRACKET (w/ DPF)

    Click here

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

    Click here

  114. REMOVE INTAKE MANIFOLD

    Click here

  115. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

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


    1. Install the No. 1 engine hanger and No. 2 engine hanger to the cylinder head sub-assembly and cylinder head LH with the 4 bolts as shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      B0019VHE01

      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

  117. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  118. REMOVE ENGINE ASSEMBLY


    1. B0018QA

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

    2. Remove the 4 bolts from the front engine mounting insulator RH and front engine mounting insulator 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.

  119. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. B0018DC

      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. B001AWS

      Remove the 8 bolts.

    3. B001986E02

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

  120. INSTALL ENGINE STAND


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

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

  121. REMOVE FRONT ENGINE MOUNTING INSULATOR RH

    Click here

  122. REMOVE FRONT ENGINE MOUNTING INSULATOR LH

    Click here