ENGINE UNIT(w/ Glow Plug Controller) REMOVAL

PROCEDURE


  1. REMOVE ENGINE COVER BRACKET


    1. A01LYWQ

      Remove the bolt and engine cover bracket from the engine mounting bracket RH.

  2. REMOVE GENERATOR ASSEMBLY


    1. A01LW8Y

      Remove the 2 bolts and generator assembly from the engine mounting bracket RH and generator bracket.

  3. REMOVE GENERATOR BRACKET


    1. A01LYKL

      Remove the 2 bolts and generator bracket from the cylinder block sub-assembly.

  4. REMOVE EGR WITH COOLER PIPE ASSEMBLY


    1. A01LZ0M

      Disengage the clamp to separate the connector from the EGR with cooler pipe assembly.

    2. A01LZ1T

      Disconnect the 3 vacuum transmitting hoses from the EGR with cooler pipe assembly.

    3. Disconnect the vacuum hose from the EGR with cooler pipe assembly.

    4. Slide the hose clip and disconnect the No. 2 oil cooler hose from the EGR with cooler pipe assembly.

    5. Slide the hose clip and disconnect the No. 2 water by-pass hose from the EGR with cooler pipe assembly.

    6. A01M0ZK

      Remove the 5 bolts, nut and EGR with cooler pipe assembly from the EGR valve (electric EGR control valve assembly), No. 1 EGR cooler bracket and cylinder head sub-assembly.

    7. A01M2MX

      Remove the EGR pipe gasket from the EGR with cooler pipe assembly.

    8. A01M0YO

      Remove the EGR inlet gasket from the EGR valve (electric EGR control valve assembly).

  5. REMOVE NO. 1 EGR COOLER BRACKET


    1. A01M06P

      Remove the 2 bolts and No. 1 EGR cooler bracket from the cylinder head sub-assembly.

  6. REMOVE HARNESS BRACKET (for LHD)


    1. A01LYHO

      Disconnect the vacuum hose from the vacuum pump assembly.

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

  7. REMOVE HARNESS BRACKET (for RHD)


    1. A01LYUJ

      Disconnect the vacuum hose from the vacuum pump assembly.

    2. Remove the bolt and harness bracket from the cylinder head cover sub-assembly.

  8. REMOVE EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    Click here

  9. REMOVE ENGINE OIL LEVEL DIPSTICK


    1. A01LVXD

      Remove the engine oil level dipstick from the engine oil level dipstick guide.

  10. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01LXW5

      Remove the bolt and engine oil level dipstick guide from the intake air connector and oil pan sub-assembly.

    2. A01M1DR

      Remove the O-ring from the engine oil level dipstick guide.

  11. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY


    1. A01LZ4M

      Disengage the clamp to separate the vacuum transmitting hose assembly from the No. 2 oil cooler hose.

    2. Slide the hose clip and disconnect the No. 3 water by-pass hose from the intake air connector with diesel throttle body.

    3. A01M0PK

      Remove the 2 bolts, 2 nuts and intake air connector with diesel throttle body from the cylinder head sub-assembly.

    4. A01LVBQ

      Remove the intake air connector gasket from the cylinder head sub-assembly.

  12. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  13. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01M31E

      Remove the bolt and No. 2 injection pipe clamp from the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly.

    2. A01LX79

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the fuel inlet pipe sub-assembly from the supply pump assembly and common rail assembly.

      Note

      To prevent contamination by foreign matter, after removing the fuel inlet pipe sub-assembly, protect the connecting portions of the supply pump assembly and common rail assembly with plastic bags.

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE NO. 2 FUEL HOSE


    1. A01M170

      Slide the 2 hose clips and remove the No. 2 fuel hose from the No. 2 nozzle leakage pipe and common rail assembly.

  19. REMOVE NO. 1 FUEL HOSE


    1. A01LZ0OC01
      *1 Union Bolt
      *2 Gasket

      Slide the hose clip and disconnect the No. 1 fuel hose from the No. 2 nozzle leakage pipe.

    2. Remove the union bolt and No. 1 fuel hose and gasket from the supply pump assembly.

  20. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01M0CA

      Remove the 2 bolts and No. 2 nozzle leakage pipe from the fuel pump protector and cylinder head cover sub-assembly.

  21. REMOVE FUEL PUMP PROTECTOR

    Click here

  22. REMOVE SUPPLY PUMP ASSEMBLY

    Click here

  23. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01LWLB

      Remove the 4 glow plug screw grommets.

    2. A01LWR0

      Remove the 4 nuts and No. 1 glow plug connector from each glow plug assembly.

  24. REMOVE GLOW PLUG ASSEMBLY

    Click here

  25. REMOVE COMMON RAIL ASSEMBLY


    1. A01LXW9

      Disengage the clamp to separate the No. 4 water by-pass hose from the common rail assembly.

    2. Slide the hose clip and remove the No. 4 water by-pass hose from the water inlet pipe.

    3. A01LUXP

      Remove the 2 bolts and common rail assembly from the cylinder head sub-assembly.

  26. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

  27. REMOVE NOZZLE HOLDER CLAMP SEAT

    Click here

  28. REMOVE INJECTOR ASSEMBLY

    Click here

  29. REMOVE INJECTION NOZZLE SEAT

    Click here

  30. REMOVE OIL COOLER HOSE


    1. A01M3AP

      Slide the 2 hose clips and remove the oil cooler hose from the water by-pass pipe sub-assembly and oil cooler assembly.

  31. REMOVE NO. 2 OIL COOLER HOSE


    1. A01M1JP

      Disengage the 4 hose clamps to separate the No. 2 oil cooler hose from the 2 clamps and water by-pass pipe sub-assembly.

    2. Slide the hose clip and remove the No. 2 oil cooler hose from the oil filter bracket sub-assembly.

  32. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A01M0P7

      Slide the hose clip and remove the No. 3 water by-pass hose from the water by-pass pipe sub-assembly.

  33. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A01M2SB

      Slide the hose clip and remove the No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

  34. REMOVE NO. 1 TURBO WATER HOSE


    1. A01LYDC

      Slide the hose clip and remove the No. 1 turbo water hose from the water by-pass pipe sub-assembly.

  35. REMOVE NO. 2 TURBO WATER HOSE


    1. A01LVJ7

      Slide the hose clip and remove the No. 2 turbo water hose from the water by-pass pipe sub-assembly.

  36. REMOVE NO. 6 WATER BY-PASS HOSE


    1. A01LZK2

      Slide the 2 hose clips and remove the No. 6 water by-pass hose from the water by-pass pipe sub-assembly and water outlet sub-assembly.

  37. DISCONNECT WATER BY-PASS HOSE


    1. A01LV9M

      Slide the hose clip and disconnect the water by-pass hose from the tube connector.

  38. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01M0PQ

      Remove the 3 clamps from the water by-pass pipe sub-assembly.

    2. A01LX8S

      Remove the 3 bolts and water by-pass pipe sub-assembly from the No. 2 turbocharger stay, cylinder head sub-assembly, cylinder block sub-assembly and water inlet housing.

    3. A01LYTJ

      Slide the hose clip and remove the water by-pass hose from the water by-pass pipe sub-assembly.

    4. A01LWDL

      Remove the O-ring from the water by-pass pipe sub-assembly.

  39. REMOVE WATER INLET HOSE RH


    1. A01LZMO

      Slide the 2 hose clips and remove the water inlet hose RH from the water outlet sub-assembly and water inlet pipe.

  40. REMOVE WATER INLET HOSE LH


    1. A01M1UF

      Slide the 2 hose clips and remove the water inlet hose LH from the water inlet pipe and water inlet housing.

  41. REMOVE WATER INLET PIPE


    1. A01LVVD

      Remove the 2 bolts and water inlet pipe from the cylinder block sub-assembly.

  42. REMOVE VACUUM PUMP ASSEMBLY


    1. A01M04E

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

    2. A01LZZG

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

  43. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01M1IW

      Remove the 2 bolts and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.

  44. REMOVE HARNESS BRACKET


    1. A01LZEQ

      Remove the bolt and harness bracket from the timing chain cover sub-assembly.

  45. REMOVE NO. 2 TURBOCHARGER STAY


    1. A01LV6F

      Remove the 2 bolts and No. 2 turbocharger stay from the cylinder head sub-assembly.

  46. REMOVE OIL PAN COVER


    1. A01M0ML

      Remove the 2 bolts, 2 plate washers and oil pan cover from the oil pan sub-assembly.

  47. REMOVE NO. 2 OIL PAN COVER SILENCER


    1. A01LV7G

      Remove the 2 bolts, 2 plate washers and No. 2 oil pan cover silencer from the oil pan sub-assembly.