ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. DISCONNECT ENGINE WIRE

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2. REMOVE FAN AND GENERATOR V BELT

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3. REMOVE COOLER COMPRESSOR ASSEMBLY WITH PULLEY

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4. REMOVE COMPRESSOR STAY

   
   

   1. 

      Remove the compressor stay from the cylinder block assembly.

5. REMOVE GENERATOR ASSEMBLY

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6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

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7. REMOVE IDLER PULLEY COVER PLATE

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8. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

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9. REMOVE NO. 4 WATER BY-PASS PIPE

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10. REMOVE ENGINE MOUNTING BRACKET

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11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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12. REMOVE VACUUM PUMP ASSEMBLY

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13. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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14. REMOVE NO. 7 WATER BY-PASS HOSE

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15. DISCONNECT NO. 8 WATER BY-PASS HOSE

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16. REMOVE EGR VALVE BRACKET

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17. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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19. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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20. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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21. REMOVE INJECTION PIPE SUB-ASSEMBLY

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22. REMOVE NO. 4 FUEL HOSE

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23. REMOVE COMMON RAIL ASSEMBLY

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24. REMOVE INTAKE MANIFOLD INSULATOR

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25. REMOVE DIESEL TURBO PRESSURE SENSOR

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26. REMOVE NO. 1 GAS FILTER

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27. REMOVE GAS FILTER BRACKET

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28. REMOVE ENGINE COVER BRACKET

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29. REMOVE NO. 2 INTAKE MANIFOLD

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30. REMOVE INTAKE MANIFOLD

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31. 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.

32. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

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33. REMOVE WATER BY-PASS HOSE

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34. REMOVE NO. 6 WATER BY-PASS HOSE

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35. REMOVE NO. 8 WATER BY-PASS HOSE

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36. REMOVE NO. 4 WATER BY-PASS HOSE

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37. REMOVE NO. 2 WATER BY-PASS PIPE

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38. REMOVE FUEL HOSE PROTECTOR

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39. REMOVE FUEL TUBE SUB-ASSEMBLY

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40. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

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41. REMOVE FUEL INJECTOR SEAL

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42. REMOVE NO. 3 FUEL HOSE

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43. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    
    

    1. 

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

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

44. REMOVE NO. 3 WATER BY-PASS PIPE

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45. REMOVE NO. 1 TURBO OIL PIPE

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46. REMOVE VACUUM REGULATING VALVE ASSEMBLY

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47. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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48. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

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49. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR

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50. REMOVE MANIFOLD STAY

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51. REMOVE NO. 2 MANIFOLD STAY

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52. REMOVE NO. 2 EXHAUST MANIFOLD STAY

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53. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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54. REMOVE NO. 2 WATER BY-PASS HOSE

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55. REMOVE EGR COOLER WITH PIPE ASSEMBLY

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56. REMOVE TURBO OIL OUTLET PIPE

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57. REMOVE NO. 1 TURBO INSULATOR

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58. DISCONNECT NO. 3 WATER BY-PASS HOSE

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59. REMOVE NO. 5 WATER BY-PASS PIPE

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60. REMOVE NO. 2 TURBO OIL PIPE

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61. REMOVE TURBOCHARGER STAY

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62. REMOVE TURBOCHARGER SUB-ASSEMBLY

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63. REMOVE EXHAUST MANIFOLD

    
    

    1. 

       Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

64. REMOVE DRIVE SHAFT BEARING BRACKET

    
    

    1. 

       Remove the 3 bolts and drive shaft bearing bracket.