ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of ECM

  • Learning values save

  • Learning values write

  • Vehicle Identification Number (VIN) registration

  • Engine starting

  • DTC P0630 is output

Click here

Code registration (Immobiliser system) Engine start function See the Service Bulletin for the registration method.
Replacement of engine assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

Click here

Replacement of fuel supply pump assembly Supply Pump Initialization Engine startability

Click here

Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

Click here

Replacement of diesel throttle body assembly Perform initialization -

Click here

Replacement of timing belt Mode reset operation

  • Does not illuminate when replacement is necessary

  • Illuminates when replacement is not necessary

Click here

CAUTION:

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

B003Q0P

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 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)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  4. REMOVE NO. 2 ENGINE UNDER COVER

  5. DRAIN ENGINE OIL

    Click here

  6. DRAIN ENGINE COOLANT

    Click here

  7. DRAIN MANUAL TRANSMISSION OIL

    Click here

  8. DRAIN POWER STEERING FLUID

  9. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose from the hood sub-assembly.

    2. Remove the 4 bolts and hood sub-assembly from the 2 hood hinge assemblies.

  10. REMOVE RADIATOR ASSEMBLY

    Click here

  11. REMOVE NO. 1 INTAKE PIPE


    1. B003J2I

      Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose from the gas filter.

    3. Loosen the 2 clamps.

    4. Remove the bolt and disconnect the No. 2 air cleaner pipe together with the 2 air hoses.

  12. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  13. DISCONNECT ENGINE WIRE


    1. Remove the ECM.

      Click here

    2. B003SFC

      Disconnect the 3 connectors from the injector driver.

    3. B003JFS

      Detach the grommet and pull out the engine wire from the cabin.

  14. REMOVE AIR CLEANER CAP AND HOSE

    Click here

  15. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  16. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  17. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. Slide the 2 clamps and disconnect the water hose sub-assembly from the water outlet and heater pipe.

  18. DISCONNECT FUEL HOSE


    1. B003OS7

      Slide the 2 clamps and disconnect the No. 1 fuel hose and No. 2 fuel hose from the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly.

  19. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B003M66

      Slide the clamp and disconnect the union to connector tube hose from the No. 1 hose to hose tube.

  20. DISCONNECT WIRE HARNESS


    1. B003S63

      Detach the 3 clips and remove the No. 1 relay block cover upper from the engine room relay block sub-assembly.

    2. B003LP1

      Detach the 2 clips and remove the No. 1 relay block cover side from the engine room relay block sub-assembly.

    3. B003LJU

      Remove the nut and disconnect the wire to wire from the engine room relay block sub-assembly.

    4. B003PEI

      Disconnect the 2 connectors from the engine room relay block sub-assembly.

    5. B003JZW

      Detach the clamp and remove the 2 bolts and disconnect the No. 2 engine wire.

    6. B003QYC

      Remove the nut and disconnect the engine room main wire from the battery positive cable.

  21. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. Loosen the 2 nuts and remove the battery clamp sub-assembly from the body.

  22. REMOVE BATTERY

  23. REMOVE BATTERY TRAY

  24. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. B003NSU

      Slide the clamp and disconnect the oil reservoir to pump hose from the vane pump assembly.

    2. B003QH4

      Disconnect the pressure feed tube assembly from the vane pump assembly.

  25. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. Remove the 4 bolts and disconnect the cooler compressor assembly from the No. 1 compressor mounting bracket.

      Tech Tips

      It is not necessary to completely remove the cooler compressor assembly. With the hoses connected to the cooler compressor assembly, hang the cooler compressor assembly on the vehicle body with a rope.

  26. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  27. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  28. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  29. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  30. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  31. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. B003POBN01

      Using SST, hold the crankshaft pulley sub-assembly.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. B003PYF

      Remove the 8 bolts and flywheel sub-assembly from the crankshaft.

  32. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate from the cylinder block sub-assembly.

  33. INSTALL ENGINE HANGER


    1. B003L0LC01
      *1 No. 1 Engine Hanger Upper
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger upper and No. 2 engine hanger with 2 bolts as shown in the illustration.

      Torque:
      for No. 1 engine hanger upper
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

      Part No.

      No. 1 engine hanger upper 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 90105-T0164 and 90119-T0065

      Note

      Install the engine hangers with new bolts.

  34. REMOVE ENGINE ASSEMBLY


    1. Attach an engine sling device and hang the engine assembly with a chain block.

    2. B003K0I

      Remove the 4 bolts and 4 nuts from the body.

    3. Remove the engine assembly by operating the engine sling device and chain block.

      Note


      • Make sure that the engine assembly is clear of all wiring and hoses.

      • While lowering the engine assembly from the vehicle, do not allow it to contact the vehicle.

  35. INSTALL ENGINE TO ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


    1. Install the engine assembly to an engine stand with the bolts.

    2. Remove the 2 bolts and No. 1 engine hanger upper and No. 2 engine hanger.

  36. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  37. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B003ME2C01
      *a RH Side
      *b LH Side

      Remove the 2 nuts and 2 front engine mounting insulators from the 2 front engine mounting brackets.