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 (w/ EGR Cooler)

    Click here

  14. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY (w/o EGR Cooler)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B003L7J

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B003MRE

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the EGR valve adapter sub-assembly.

  15. 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.

  16. 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.

  17. REMOVE VACUUM CONTROL VALVE SET (w/ EGR Cooler)

    Click here

  18. 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

      w/ EGR Cooler:


      1. 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.

    2. w/o EGR Cooler:


      1. B003L08C01
        *1 No. 6 Water By-pass Hose
        *2 No. 7 Water By-pass Hose
        *3 No. 2 Turbo 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 No. 2 turbo water hose from the EGR valve adapter sub-assembly.

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

  19. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Cooler)

    Click here

  20. REMOVE EGR VALVE ADAPTER SUB-ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B003MRV

      Remove the 4 bolts and EGR valve adapter sub-assembly with electric EGR control valve assembly from the intake manifold.

  21. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  22. 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.

  23. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  24. REMOVE MANIFOLD STAY

    Click here

  25. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  26. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  27. REMOVE NO. 2 FUEL HOSE

    Click here

  28. REMOVE NO. 1 FUEL HOSE

    Click here

  29. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ Pressurized Fuel Filter)

    Click here

  30. REMOVE NO. 3 FUEL PIPE (w/ Pressurized Fuel Filter)

    Click here

  31. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  32. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  33. REMOVE INTAKE MANIFOLD

    Click here

  34. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  35. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  36. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B003K6M

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

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

    Click here

  38. REMOVE COMMON RAIL ASSEMBLY

    Click here

  39. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  40. REMOVE GLOW PLUG ASSEMBLY

    Click here

  41. REMOVE HOSE BRACKET


    1. B003PY7

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

  42. REMOVE DIESEL FUEL FILTER ASSEMBLY (w/ Pressurized Fuel Filter)


    1. B003LMA

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

  43. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o Pressurized Fuel Filter)


    1. B003OUG

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

  44. 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.

  45. 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.

  46. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  47. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ EGR Cooler)

    Click here

  48. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o EGR Cooler)


    1. B003PKK

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.

  49. REMOVE NO. 1 TURBO INSULATOR (w/ EGR Cooler)

    Click here

  50. REMOVE NO. 1 TURBO INSULATOR (w/o EGR Cooler)


    1. B003LHX

      Remove the 3 bolts and No. 1 turbo insulator from the turbine outlet elbow and turbocharger sub-assembly.

  51. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY (w/ EGR Cooler)

    Click here

  52. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY (w/o EGR Cooler)


    1. B003J35

      Remove the bolt, 2 nuts and No. 2 exhaust pipe support stay from the cylinder block sub-assembly and turbine outlet elbow.

  53. REMOVE EXHAUST PIPE SUPPORT STAY (w/ EGR Cooler)

    Click here

  54. REMOVE EXHAUST PIPE SUPPORT STAY (w/o EGR Cooler)


    1. B003PBG

      Remove the 3 bolts and exhaust pipe support stay from the cylinder block sub-assembly and turbine outlet elbow.

  55. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  56. REMOVE TURBINE OUTLET ELBOW (w/o EGR Cooler)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B003M33

      Remove the nut, exhaust pipe clamp and turbine outlet elbow from the turbocharger sub-assembly.

    2. Remove the gasket.

  57. REMOVE PCV HOSE

    Click here

  58. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  59. 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.

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

    Click here

  61. REMOVE TURBOCHARGER STAY

    Click here

  62. REMOVE TURBO OIL OUTLET PIPE

    Click here

  63. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  64. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  65. REMOVE EXHAUST MANIFOLD

    Click here

  66. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  67. 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.

  68. 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.

  69. REMOVE WATER INLET


    1. B003KSI

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

  70. REMOVE THERMOSTAT

    Click here

  71. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  72. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

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


    1. B003OT3C03
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      w/ EGR Cooler:

      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.

  74. 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.

  75. 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.

  76. REMOVE CRANKSHAFT PULLEY

    Click here