ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. REMOVE COMPRESSOR STAY

   
   

   1. 

      Remove the compressor stay from the cylinder block sub-assembly.

2. REMOVE GENERATOR ASSEMBLY

   
   

   1. 

      Remove the 3 bolts and generator assembly.

3. REMOVE VACUUM PUMP ASSEMBLY

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4. REMOVE IDLER PULLEY COVER PLATE

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5. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

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6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

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7. REMOVE NO. 4 WATER BY-PASS PIPE

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8. REMOVE STUD BOLT

   Tech Tips

   Perform this procedure only when replacement of the stud bolt is necessary.

   
   

   1. 

      Using an 8 mm socket wrench, remove the stud bolt from the engine mounting bracket.

9. REMOVE ENGINE MOUNTING BRACKET

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10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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11. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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12. DISCONNECT NO. 7 WATER BY-PASS HOSE

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13. DISCONNECT NO. 8 WATER BY-PASS HOSE

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14. REMOVE EGR VALVE BRACKET

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15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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18. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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19. REMOVE INJECTION PIPE SUB-ASSEMBLY

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20. REMOVE NO. 4 FUEL HOSE

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21. REMOVE COMMON RAIL ASSEMBLY

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22. REMOVE INTAKE MANIFOLD INSULATOR

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23. REMOVE DIESEL TURBO PRESSURE SENSOR

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24. REMOVE NO. 1 GAS FILTER

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25. REMOVE GAS FILTER BRACKET

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26. REMOVE ENGINE COVER BRACKET

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27. REMOVE NO. 2 INTAKE MANIFOLD

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28. REMOVE INTAKE MANIFOLD

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29. REMOVE GLOW PLUG ASSEMBLY

    
    

    1. 

       Remove the 4 glow plug screw grommets.

    2. Remove the 4 nuts and No. 1 glow plug connector.

    3. Using a 10 mm deep socket wrench, remove the 4 glow plug assemblies.

30. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

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31. REMOVE WATER BY-PASS HOSE

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32. REMOVE NO. 6 WATER BY-PASS HOSE

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33. REMOVE NO. 8 WATER BY-PASS HOSE

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34. REMOVE NO. 2 WATER BY-PASS PIPE

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35. REMOVE NO. 4 WATER BY-PASS HOSE

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36. REMOVE FUEL TUBE SUB-ASSEMBLY

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37. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

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38. REMOVE FUEL INJECTOR SEAL

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39. REMOVE NO. 3 FUEL HOSE

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40. REMOVE SUPPLY PUMP ASSEMBLY

    
    

    1. 

       Remove the 2 bolts, supply pump assembly and No. 1 supply pump drive coupling.

    2. Remove the O-ring from the supply pump assembly.

41. REMOVE FUEL HOSE PROTECTOR

    
    

    1. 

       Remove the bolt and fuel hose protector.

42. REMOVE NO. 3 WATER BY-PASS PIPE

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43. REMOVE NO. 1 TURBO OIL PIPE

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44. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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45. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

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46. REMOVE NO. 1 WIRE HARNESS CLAMP BRACKET

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47. REMOVE NO. 4 MANIFOLD CONVERTER INSULATOR

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48. REMOVE MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY

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49. REMOVE MANIFOLD STAY

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50. REMOVE NO. 2 MANIFOLD STAY

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51. REMOVE NO. 2 EXHAUST MANIFOLD STAY

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52. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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53. REMOVE NO. 2 WATER BY-PASS HOSE

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54. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

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55. REMOVE TURBOCHARGER SUB-ASSEMBLY

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56. REMOVE DRIVE SHAFT BEARING BRACKET

    
    

    1. 

       Remove the 3 bolts and drive shaft bearing bracket.