ENGINE UNIT REMOVAL

PROCEDURE


  1. PRECAUTION

    Note


    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A01T959E01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST
      PZ4TB-04941-79

  2. REMOVE ENGINE COVER

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  3. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  4. REMOVE V-RIBBED BELT

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  5. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

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  6. REMOVE GENERATOR ASSEMBLY

    Click here

  7. REMOVE IDLER PULLEY ASSEMBLY


    1. A01TA45

      Using a T50 "TORX" socket wrench, loosen the bolt to remove the idler pulley assembly.

      Tech Tips

      The bolt cannot be removed from the idler pulley assembly.

  8. REMOVE ENGINE MOUNTING BRACKET


    1. A01TAHF

      Using an E12 "TORX" socket wrench, remove the 3 bolts and engine mounting bracket.

    2. Remove the 2 stud bolts from the engine mounting bracket.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01TCRQ

      Remove the 2 bolts and V-ribbed belt tensioner assembly.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  12. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

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  13. REMOVE NO. 2 VACUUM HOSE ASSEMBLY


    1. A01TA9Q

      Remove the bolt, nut and No. 2 vacuum hose assembly from the No. 2 engine hanger.

  14. REMOVE NO. 1 VACUUM PIPE

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  15. REMOVE INTAKE MANIFOLD

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  16. REMOVE FUEL FEED PIPE SUB-ASSEMBLY


    1. A01TAZX

      Disconnect the nozzle leakage pipe assembly from the fuel feed pipe sub-assembly.

    2. A01TCSL

      Loosen the 2 clamps and disconnect the 2 fuel hoses from the fuel supply pump assembly.

    3. Disconnect the fuel return tube from the common rail assembly.

    4. Detach the fuel hose clamp.

    5. Remove the 2 bolts and fuel feed pipe sub-assembly.

  17. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  19. REMOVE TURBO OIL OUTLET PIPE

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  20. DISCONNECT NO. 1 TURBO OIL PIPE

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  21. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  22. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

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  23. REMOVE EXHAUST MANIFOLD

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  24. REMOVE NO. 1 TURBO OIL PIPE


    1. A01TDA3

      Remove the 2 nuts, union bolt, 2 gaskets and No. 1 turbo oil pipe.

  25. REMOVE NO. 2 TURBO INSULATOR


    1. A01TAWT

      Remove the 3 bolts and No. 2 turbo insulator.

  26. REMOVE TURBOCHARGER STAY


    1. A01T9IK

      Remove the 2 bolts and turbocharger stay.

  27. REMOVE EGR VALVE BRACKET


    1. A01TBXN

      Remove the 2 bolts and EGR valve bracket from the cylinder head sub-assembly.

  28. REMOVE NO. 2 ENGINE HANGER


    1. A01TC4F

      Remove the 2 bolts and No. 2 engine hanger from the cylinder head sub-assembly.

  29. REMOVE NO. 1 ENGINE HANGER


    1. A01T92V

      Remove the bolt and No. 1 engine hanger from the cylinder head sub-assembly.

  30. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  31. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  32. REMOVE COMMON RAIL ASSEMBLY

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  33. REMOVE GLOW PLUG ASSEMBLY

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  34. REMOVE EGR BYPASS VALVE SWITCHING VALVE

    Click here

  35. REMOVE VACUUM CONTROL VALVE BRACKET

    Click here

  36. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01TAKO

      Using a T50 "TORX" socket wrench, remove the 3 bolts and drive shaft bearing bracket.