ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE VACUUM PUMP ASSEMBLY

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  2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  3. REMOVE 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 TURBO OIL OUTLET HOSE

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

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  11. REMOVE TURBOCHARGER STAY

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  12. REMOVE VENTILATION TUBE SUB-ASSEMBLY

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  13. REMOVE TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD

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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 NO. 2 EXHAUST MANIFOLD

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  25. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (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


    1. A01WQTP

      w/o Viscous Heater:

      Remove the 2 bolts and timing gear cover insulator.

    2. A01WTPL

      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

    A01WRRZ

  34. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  35. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET


    1. A01WR6B

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

  36. REMOVE WATER OUTLET


    1. A01WVG4

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

  37. REMOVE WATER OUTLET PIPE


    1. A01WR9A

      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. A01WSZU

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

    2. A01WQ85

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

    3. A01WRU8

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

  39. REMOVE NO. 1 GLOW PLUG CONNECTOR

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  40. REMOVE GLOW PLUG ASSEMBLY

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  41. REMOVE FUEL PUMP MOTOR WIRE


    1. A01WS76

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

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

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

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  44. REMOVE FAN BRACKET SUB-ASSEMBLY

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

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

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


    1. B001988

      Remove the 3 bolts and cylinder head cover silencer RH.

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


    1. B0018MC

      Remove the 3 bolts and cylinder head cover silencer LH.

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


    1. A01WR86

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

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


    1. A01WWKM

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

  51. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET


    1. A01WWUZ

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

  52. REMOVE AIR TUBE SUPPORT


    1. A01WVNG

      Remove the 2 bolts and air tube support.

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


    1. A01WQC5

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

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


    1. A01WUEV

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 4 vacuum transmitting pipe sub-assembly.

  55. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01WUCZ

      Remove the 4 bolts and engine mounting bracket RH.

  56. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    A01WQCI

  57. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A01WPJR

      Detach the 2 wire harness clamps.

    2. A01WR2A

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

  58. REMOVE TURBOCHARGER WIRE


    1. A01WS0B

      Detach the 3 wire harness clamps.

    2. Remove the 2 bolts and turbocharger wire.

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


    1. A01WT6R

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe sub-assembly.

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


    1. A01WPB5

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

  61. REMOVE ENGINE MOUNTING BRACKET LH


    1. A01WWPA

      Remove the 4 bolts and engine mounting bracket LH.

  62. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    A01WS16

  63. REMOVE OIL TANK BRACKET


    1. A01WQT0

      Remove the bolt and oil tank bracket.

  64. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET


    1. A01WVYI

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

  65. REMOVE NO. 3 ENGINE HANGER


    1. A01WUKN

      Remove the 2 bolts and No. 3 engine hanger.

  66. REMOVE OIL FILTER BRACKET DRAIN COCK ASSEMBLY


    1. B00192J

      Remove the oil filter drain cock plug.

    2. A01WW3D

      Remove the oil filter drain cock body.

      Tech Tips

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

  67. REMOVE OIL PRESSURE REGULATOR ASSEMBLY


    1. A01WRDH

      Using a 26 mm wrench, remove the oil pressure regulator assembly 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. A01WU74E01

      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.

  68. REMOVE STIFFENER INSULATOR RH

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  69. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01WTVHE05
      Text in Illustration
      *a Timing Mark

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

  70. REMOVE COMPRESSOR BRACKET


    1. A01WU7C

      Remove the bolt and compressor bracket.

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

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  72. REMOVE FUEL INJECTOR SEAL (w/ DPF)

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