CAUTION / NOTICE / HINT
Note
When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
PROCEDURE
DISCONNECT ENGINE WIRE
REMOVE FAN AND GENERATOR V BELT
REMOVE COOLER COMPRESSOR ASSEMBLY WITH PULLEY
REMOVE COMPRESSOR STAY
Remove the compressor stay from the cylinder block sub-assembly.
REMOVE GENERATOR ASSEMBLY
REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
REMOVE IDLER PULLEY COVER PLATE
REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
REMOVE NO. 4 WATER BY-PASS PIPE
REMOVE ENGINE MOUNTING BRACKET
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
REMOVE VACUUM PUMP ASSEMBLY
REMOVE DIESEL THROTTLE BODY ASSEMBLY
REMOVE NO. 7 WATER BY-PASS HOSE
DISCONNECT NO. 8 WATER BY-PASS HOSE
REMOVE EGR VALVE BRACKET
REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
REMOVE INJECTION PIPE SUB-ASSEMBLY
REMOVE NO. 4 FUEL HOSE
REMOVE COMMON RAIL ASSEMBLY
REMOVE INTAKE MANIFOLD INSULATOR
REMOVE DIESEL TURBO PRESSURE SENSOR
REMOVE NO. 1 GAS FILTER
REMOVE GAS FILTER BRACKET
REMOVE ENGINE COVER BRACKET
REMOVE NO. 2 INTAKE MANIFOLD
REMOVE INTAKE MANIFOLD
REMOVE GLOW PLUG ASSEMBLY
Remove the 4 glow plug screw grommets.
Remove the 4 nuts and No. 1 glow plug connector.
Using a 10 mm deep socket wrench, remove the 4 glow assemblies.
REMOVE NO. 1 CYLINDER BLOCK INSULATOR
REMOVE WATER BY-PASS HOSE
REMOVE NO. 6 WATER BY-PASS HOSE
REMOVE NO. 8 WATER BY-PASS HOSE
REMOVE NO. 4 WATER BY-PASS HOSE
REMOVE NO. 2 WATER BY-PASS PIPE
REMOVE FUEL HOSE PROTECTOR
REMOVE FUEL TUBE SUB-ASSEMBLY
REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY
REMOVE FUEL INJECTOR SEAL
REMOVE NO. 3 FUEL HOSE
REMOVE FUEL SUPPLY PUMP ASSEMBLY
Remove the 2 bolts, fuel supply pump assembly and No. 1 supply pump drive coupling.
Remove the O-ring from the fuel supply pump assembly.
REMOVE NO. 3 WATER BY-PASS PIPE
REMOVE NO. 1 TURBO OIL PIPE
REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY
REMOVE NO. 1 WIRING HARNESS CLAMP BRACKET
REMOVE NO. 4 MANIFOLD CONVERTER INSULATOR
REMOVE MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY
REMOVE MANIFOLD STAY
REMOVE NO. 2 MANIFOLD STAY
REMOVE NO. 2 EXHAUST MANIFOLD STAY
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
REMOVE NO. 2 WATER BY-PASS HOSE
REMOVE EGR COOLER WITH PIPE ASSEMBLY
REMOVE TURBOCHARGER SUB-ASSEMBLY
REMOVE EXHAUST MANIFOLD
Remove the 8 nuts, 8 collars, exhaust manifold and gasket.
REMOVE DRIVE SHAFT BEARING BRACKET
Remove the 3 bolts and drive shaft bearing bracket.