ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge valve or fuel pressure sensor, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. REMOVE NO. 2 HOSE TO HOSE TUBE


    1. B003QU2

      Slide the clamp and disconnect the union to check valve hose from the vacuum pump assembly.

    2. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose bracket.

  2. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  3. REMOVE ENGINE WIRE

  4. REMOVE INTERCOOLER AIR TUBE

    Click here

  5. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  6. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  7. REMOVE DIFFERENTIAL PRESSURE SENSOR

    Click here

  8. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    Click here

  9. REMOVE NO. 1 VACUUM PIPE

    Click here

  10. REMOVE NO. 2 VACUUM PIPE

    Click here

  11. REMOVE PIPE CLAMP

    Click here

  12. REMOVE ENGINE COVER BRACKET


    1. B003M18

      Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

  13. REMOVE GAS FILTER

    Click here

  14. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  15. REMOVE EGR VALVE BRACKET

    Click here

  16. REMOVE NO. 2 EGR PIPE

    Click here

  17. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  18. REMOVE CONNECTING WIRE


    1. B003LR2

      Disconnect the connector from the common rail assembly.

    2. Detach the 2 clamps and remove the connecting wire from the hose bracket.

  19. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B003M6L

      Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 gaskets from the exhaust manifold and electric EGR control valve assembly.

    3. B003LI8

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  20. REMOVE VACUUM CONTROL VALVE SET

    Click here

  21. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B003JEYC01
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
      *3 Water Hose

      Slide the clamp and disconnect the No. 6 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    2. Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    4. Remove the 2 bolts and No. 4 water by-pass pipe sub-assembly from the intake manifold.

  22. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  24. REMOVE NO. 2 FUEL PIPE


    1. B003OGX

      Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

    2. Remove the bolt and No. 2 fuel pipe from the manifold stay.

  25. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  26. REMOVE MANIFOLD STAY

    Click here

  27. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  28. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  29. REMOVE NO. 2 FUEL HOSE

    Click here

  30. REMOVE NO. 1 FUEL HOSE

    Click here

  31. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  32. REMOVE NO. 3 FUEL PIPE

    Click here

  33. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  34. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  35. REMOVE INTAKE MANIFOLD

    Click here

  36. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  37. REMOVE NO. 1 FUEL PIPE

    Click here

  38. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  39. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B003K6M

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

  40. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  41. REMOVE COMMON RAIL ASSEMBLY

    Click here

  42. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  43. REMOVE GLOW PLUG ASSEMBLY

    Click here

  44. REMOVE HOSE BRACKET


    1. B003PY7

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

  45. REMOVE DIESEL FUEL FILTER ASSEMBLY


    1. B003LMA

      Remove the 2 nuts and diesel fuel filter assembly from the cylinder block sub-assembly.

  46. REMOVE NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B003O6A

      Remove the 3 bolts, No. 5 water by-pass pipe sub-assembly and gasket from the cylinder block sub-assembly.

  47. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B003QB2

      Remove the 4 bolts and No. 1 compressor mounting bracket from the cylinder block sub-assembly, timing chain case assembly and timing chain cover sub-assembly.

  48. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  49. REMOVE NO. 5 WATER BY-PASS HOSE


    1. B003R8M

      Slide the 2 clamps and disconnect the No. 5 water by-pass hose from the No. 1 injector holder and water outlet sub-assembly.

    2. Detach the clamp and remove the No. 5 water by-pass hose from the No. 1 water hose clamp bracket.

  50. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B003RXK

      Slide the clamp and disconnect the No. 4 water by-pass hose from the No. 1 injector holder.

  51. REMOVE NO. 1 INJECTOR HOLDER

    Click here

  52. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  53. REMOVE AIR FUEL RATIO SENSOR

    Click here

  54. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  55. REMOVE NO. 1 TURBO INSULATOR

    Click here

  56. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

    Click here

  57. REMOVE EXHAUST PIPE SUPPORT STAY

    Click here

  58. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  59. REMOVE PCV HOSE

    Click here

  60. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  61. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B003P1D

      Remove the 3 bolts, No. 1 water by-pass pipe and gasket from the timing chain cover sub-assembly.

  62. DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  63. REMOVE TURBOCHARGER STAY

    Click here

  64. REMOVE TURBO OIL OUTLET PIPE

    Click here

  65. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  66. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  67. REMOVE EXHAUST MANIFOLD

    Click here

  68. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  69. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B003PAH

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

    2. Remove the 2 bolts and No. 2 water by-pass pipe sub-assembly from the engine water pump assembly and water inlet.

  70. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B003QQP

      Remove the 4 bolts, 2 nuts and water outlet sub-assembly from the timing chain cover sub-assembly.

    2. Remove the gasket from the timing chain cover sub-assembly.

  71. REMOVE WATER INLET


    1. B003KSI

      Remove the 3 bolts and water inlet from the timing chain cover sub-assembly.

  72. REMOVE THERMOSTAT

    Click here

  73. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  74. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  75. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. B003NL9

      Disconnect the No. 1 vacuum transmitting hose from the vacuum pump assembly.

    2. Remove the 3 bolts and No. 1 vacuum transmitting pipe sub-assembly from the cylinder head sub-assembly.

  76. REMOVE VACUUM PUMP ASSEMBLY


    1. B003PID

      Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.

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

  77. REMOVE CAMSHAFT OIL SEAL RETAINER


    1. B003K8U

      Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-assembly.

  78. REMOVE CRANKSHAFT PULLEY

    Click here

  79. REMOVE NO. 1 WATER HOSE CLAMP BRACKET


    1. B003OIM

      Remove the bolt and No. 1 water hose clamp bracket from the timing chain case assembly.