ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • The exhaust valve is filled with sodium. Sodium is a strong alkali which can produce a dangerous chemical reaction. Be very careful when handling and disposing of it.

  • Do not intentionally expose the sodium in exhaust valve. If sodium enters your eyes, vision loss may occur. If sodium contacts your skin, burns may occur. If a fire occurs due to a chemical reaction with sodium, burns may occur.

  • If the sodium in the exhaust valve is exposed, perform all necessary preparations to safely remove and dispose of the sodium.

  • When removing a damaged exhaust valve, always wear rubber gloves and safety glasses.

  • Do not intentionality cut or break open the exhaust valve to remove the sodium.

Tech Tips


  • The sodium inside the exhaust valve is safe as long as it remains sealed inside the exhaust valve.

  • Exhaust valves filled with sodium can be identified by their "NA" identification mark.

  • Removal of the exhaust valve:

    Click here

  • Disposal of the exhaust valve:

    Click here

PROCEDURE


  1. REMOVE GENERATOR ASSEMBLY

    Click here

  2. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

    Click here

  3. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  4. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  5. REMOVE WATER BY-PASS PIPE ASSEMBLY


    1. B003U4EC01
      *1 No. 2 Turbo Water Hose
      *2 No. 9 Water By-pass Hose

      Slide the clip and disconnect the No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

    2. Slide the clip and disconnect the No. 9 water by-pass hose from the intercooler assembly.

    3. Remove the 2 bolts and water by-pass pipe assembly from the intercooler assembly and No. 2 air tube.

  6. REMOVE PURGE VALVE (PURGE VSV)


  7. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  8. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  9. REMOVE NO. 2 VENTILATION HOSE

    Click here

  10. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. B003WS9

      Disengage the clamp from the engine oil level dipstick guide.

    2. Slide the clip and disconnect the No. 3 water by-pass hose from the water outlet sub-assembly.

  11. REMOVE INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY


    1. B003TCH

      Remove the bolt and wire harness clamp bracket from the intake manifold with intercooler assembly and throttle with motor body assembly.

    2. B003WNZ

      Remove the 4 bolts, 2 nuts and intake manifold with intercooler assembly and throttle with motor body assembly.

    3. Remove the 2 No. 1 intake manifold to head gaskets from the intake manifold with intercooler assembly and throttle with motor body assembly.

  12. REMOVE FRONT ENGINE MOUNTING HEAT INSULATOR LH (w/ Front Engine Mounting Heat Insulator LH)


    1. B003TMF

      Remove the 2 bolts and front engine mounting heat insulator LH from the front No. 1 engine mounting bracket LH.

  13. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B003SYQ

      Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.

  14. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. B003T56

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. B003W9T

      Remove the bolt and engine oil level dipstick guide.

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

  16. REMOVE IGNITION COIL ASSEMBLY

    Click here

  17. REMOVE VENTILATION HOSE

    Click here

  18. REMOVE NO. 4 VENTILATION HOSE

    Click here

  19. REMOVE NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  20. REMOVE OUTLET COMPRESSOR ELBOW


    1. B003UWL

      Remove the 2 nuts and outlet compressor elbow from the turbocharger sub-assembly.

    2. Remove the gasket from the turbocharger sub-assembly.

  21. REMOVE NO. 1 HEAT INSULATOR BRACKET

    Click here

  22. REMOVE NO. 2 HEAT INSULATOR BRACKET

    Click here

  23. DISCONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  24. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  25. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  26. REMOVE SENSOR WIRE


    1. B003VQ8

      Disconnect the fuel pressure sensor connector.

    2. B003X5V

      Remove the 2 bolts and disconnect the sensor wire from the fuel delivery pipe sub-assembly.

    3. Disconnect the 4 direct fuel injector assembly connectors and remove the sensor wire.

  27. REMOVE WIRE HARNESS CLAMP BRACKET


    1. for Engine Front Side:


      1. B003VBC

        Disconnect the oil pressure sender gauge assembly connector.

      2. Remove the bolt and wire harness clamp bracket from the timing chain cover assembly.

    2. for Engine Upper Side:


      1. B003VIG

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

    3. for Engine RH Side:


      1. B003U8F

        Remove the 2 bolts and 2 wire harness clamp brackets from the stiffening crankcase assembly.

    4. for Engine Rear Side:


      1. B003TGT

        Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

  28. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

  29. REMOVE OIL FILLER CAP GASKET


    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  30. REMOVE IDLER PULLEY SUB-ASSEMBLY

    Click here

  31. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  32. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  33. REMOVE AIR CLEANER BRACKET

    Click here

  34. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

    Click here

  35. REMOVE FUEL DELIVERY PIPE (for Port Injection)

    Click here

  36. REMOVE PORT FUEL INJECTOR ASSEMBLY

    Click here

  37. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

    Click here

  38. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

    Click here

  39. REMOVE FUEL INJECTOR SEAL (for Direct Injection)

    Click here

  40. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

  41. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  42. REMOVE NO. 9 ENGINE WIRE


    1. B003WN7

      Disconnect the oil pressure switching valve assembly connector.

    2. Remove the 3 clamps and No. 9 engine wire from the No. 1 water by-pass pipe and water inlet housing.

  43. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  44. REMOVE NO. 4 WATER BY-PASS PIPE


    1. B003TG0

      Slide the clip and disconnect the No. 4 water by-pass pipe from the oil cooler assembly.

    2. Remove the 2 nuts, bolt and No. 4 water by-pass pipe from the cylinder block sub-assembly and water inlet housing.

    3. Remove the gasket from the water inlet housing.

  45. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

    Click here

  46. REMOVE WATER INLET HOUSING SUB-ASSEMBLY

    Click here

  47. REMOVE THERMOSTAT (for Cylinder Block)

    Click here