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 ENGINE COVER BRACKET


    1. B003M18

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

  8. REMOVE WATER BY-PASS PLUG (w/o Heater)


    1. B003J42

      Slide the clamp and remove the water by-pass plug from the water outlet sub-assembly.

  9. REMOVE GAS FILTER

    Click here

  10. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  11. REMOVE EGR VALVE BRACKET

    Click here

  12. REMOVE NO. 2 EGR PIPE

    Click here

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

    Click here

  14. 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.

  15. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B003M6L

      Remove the 4 nuts, bolt and No. 1 EGR pipe 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.

  16. REMOVE VACUUM CONTROL VALVE SET

    Click here

  17. 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.

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

    Click here

  19. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  20. 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.

  21. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  22. REMOVE MANIFOLD STAY

    Click here

  23. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  24. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  25. REMOVE NO. 2 FUEL HOSE

    Click here

  26. REMOVE NO. 1 FUEL HOSE

    Click here

  27. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  28. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  29. REMOVE INTAKE MANIFOLD

    Click here

  30. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  31. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  32. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B003K6M

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

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

    Click here

  34. REMOVE COMMON RAIL ASSEMBLY

    Click here

  35. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  36. REMOVE GLOW PLUG ASSEMBLY

    Click here

  37. REMOVE HOSE BRACKET


    1. B003PY7

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

  38. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. B003OUG

      Remove the 2 nuts and No. 3 nozzle leakage pipe from the cylinder block sub-assembly.

  39. 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.

  40. 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.

  41. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  42. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  43. REMOVE NO. 1 TURBO INSULATOR

    Click here

  44. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

    Click here

  45. REMOVE EXHAUST PIPE SUPPORT STAY

    Click here

  46. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  47. REMOVE PCV HOSE

    Click here

  48. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  49. 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.

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

    Click here

  51. REMOVE TURBOCHARGER STAY

    Click here

  52. REMOVE TURBO OIL OUTLET PIPE

    Click here

  53. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  54. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  55. REMOVE EXHAUST MANIFOLD

    Click here

  56. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  57. 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.

  58. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B003MQU

      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.

  59. REMOVE WATER INLET


    1. B003KSI

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

  60. REMOVE THERMOSTAT

    Click here

  61. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  62. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  63. 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.

  64. 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.

  65. 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.

  66. REMOVE CRANKSHAFT PULLEY

    Click here