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ENGINE UNIT REMOVAL

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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
    Supply pump assembly Fuel inlet 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

  • 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.

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PROCEDURE


  1. Click here

    REMOVE NO. 2 HOSE TO HOSE TUBE


    1. B0025ZK

      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. Click here

    REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  3. Click here

    REMOVE ENGINE WIRE

  4. Click here

    REMOVE INTERCOOLER AIR TUBE

    Click here

  5. Click here

    REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  6. Click here

    REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  7. Click here

    REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF)

    Click here

  8. Click here

    REMOVE EXHAUST GAS TEMPERATURE SENSOR (w/ DPF)

    Click here

  9. Click here

    REMOVE NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  10. Click here

    REMOVE NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  11. Click here

    REMOVE PIPE CLAMP (w/ DPF)

    Click here

  12. Click here

    REMOVE ENGINE COVER BRACKET


    1. B0025PF

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

  13. Click here

    REMOVE GAS FILTER

    Click here

  14. Click here

    REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  15. Click here

    REMOVE EGR VALVE BRACKET

    Click here

  16. Click here

    REMOVE NO. 2 EGR PIPE

    Click here

  17. Click here

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

    Click here

  18. Click here

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


    1. B0068KZ

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

    2. B002712C01
      *A w/ EGR System
      *B w/o EGR System

      w/ EGR System:

      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.

  19. Click here

    REMOVE CONNECTING WIRE


    1. B00258B

      Disconnect the connector from the common rail assembly.

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

  20. Click here

    REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System)


    1. B0069F2

      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. B0068JS

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

  21. Click here

    REMOVE VACUUM CONTROL VALVE SET (w/ EGR Cooler)

    Click here

  22. Click here

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


    1. B0028R0C01
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
      *3 Water Hose
      *4 No. 11 Water By-pass 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. for Cold Area Specification Vehicles:

      Detach the clamp and disconnect the No. 11 water by-pass hose from the No. 2 fuel pipe.

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

  23. Click here

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

    Click here

  24. Click here

    REMOVE EGR VALVE ADAPTER SUB-ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)


    1. B0027MO

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

  25. Click here

    REMOVE EGR VALVE ADAPTER SUB-ASSEMBLY (w/o EGR System)


    1. B0024WY

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

  26. Click here

    REMOVE EGR HOLE COVER PLATE (w/o EGR System)


    1. B00249V

      Remove the 4 nuts and 2 EGR cooler hole plates and 2 gaskets from the intake manifold and exhaust manifold.

    2. B0068JS

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

  27. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  28. Click here

    REMOVE NO. 2 FUEL PIPE


    1. B00251D

      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.

  29. Click here

    REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  30. Click here

    REMOVE MANIFOLD STAY

    Click here

  31. Click here

    REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  32. Click here

    REMOVE FUEL PUMP MOTOR WIRE

    Click here

  33. Click here

    REMOVE NO. 2 FUEL HOSE

    Click here

  34. Click here

    REMOVE NO. 1 FUEL HOSE

    Click here

  35. Click here

    REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  36. Click here

    REMOVE NO. 3 FUEL PIPE (w/ DPF)

    Click here

  37. Click here

    REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  38. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  39. Click here

    REMOVE INTAKE MANIFOLD

    Click here

  40. Click here

    REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  41. Click here

    REMOVE NO. 1 FUEL PIPE (w/ DPF)

    Click here

  42. Click here

    REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  43. Click here

    REMOVE WIRING HARNESS CLAMP BRACKET


    1. B0026T5

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

  44. Click here

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

    Click here

  45. Click here

    REMOVE COMMON RAIL ASSEMBLY

    Click here

  46. Click here

    REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  47. Click here

    REMOVE GLOW PLUG ASSEMBLY

    Click here

  48. Click here

    REMOVE HOSE BRACKET


    1. B0024IT

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

  49. Click here

    REMOVE FUEL FILTER ASSEMBLY (w/ Pressurized Fuel Filter)


    1. B0026NZ

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

  50. Click here

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


    1. B0028N5

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

  51. Click here

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


    1. B0025EA

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

  52. Click here

    REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. B002760

      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.

  53. Click here

    REMOVE IDLER PULLEY ASSEMBLY (w/o Air Conditioning System)


    1. B002737

      Remove the 3 bolts and idler pulley assembly from the cylinder block sub-assembly, timing chain case assembly and timing chain cover sub-assembly.

  54. Click here

    REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  55. Click here

    REMOVE PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  56. Click here

    REMOVE NO. 5 WATER BY-PASS HOSE (w/ DPF)


    1. B00257S

      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.

  57. Click here

    DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF)


    1. B00283S

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

  58. Click here

    REMOVE NO. 1 INJECTOR HOLDER (w/ DPF)

    Click here

  59. Click here

    REMOVE AIR FUEL RATIO SENSOR (w/ DPF)

    Click here

  60. Click here

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


  61. Click here

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


    1. B0024LH

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

  62. Click here

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


  63. Click here

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


    1. B00253H

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

  64. Click here

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


  65. Click here

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


    1. B0024W7

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

  66. Click here

    REMOVE EXHAUST PIPE SUPPORT STAY (w/ EGR Cooler)


  67. Click here

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


    1. B0025E9

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

  68. Click here

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


  69. Click here

    REMOVE TURBINE OUTLET ELBOW (w/o EGR Cooler)


    1. B0025LQ

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

    2. Remove the gasket.

  70. Click here

    REMOVE PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  71. Click here

    REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  72. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE


    1. B0028W7C02
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

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

  73. Click here

    DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  74. Click here

    REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. B0026G4

      Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly from the cylinder block sub-assembly and timing chain cover sub-assembly.

  75. Click here

    REMOVE TURBOCHARGER STAY

    Click here

  76. Click here

    REMOVE TURBO OIL OUTLET PIPE

    Click here

  77. Click here

    REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  78. Click here

    REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  79. Click here

    REMOVE EXHAUST MANIFOLD

    Click here

  80. Click here

    REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  81. Click here

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


    1. B002555

      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.

  82. Click here

    REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B00257PC01
      *A w/ DPF
      *B w/o DPF

      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.

  83. Click here

    REMOVE WATER INLET


    1. B0027R9

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

  84. Click here

    REMOVE THERMOSTAT

    Click here

  85. Click here

    REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  86. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  87. Click here

    REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. B0025B0C02
      *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.

  88. Click here

    REMOVE VACUUM PUMP ASSEMBLY


    1. B0024VR

      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.

  89. Click here

    REMOVE CAMSHAFT OIL SEAL RETAINER


    1. B00256I

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

  90. Click here

    REMOVE VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  91. Click here

    REMOVE CRANKSHAFT PULLEY COVER

    Click here

  92. Click here

    REMOVE CRANKSHAFT PULLEY

    Click here

  93. Click here

    REMOVE NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF)


    1. B002886

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