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
    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.

PROCEDURE


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


    1. B0025IW

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

  8. REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF)

    Click here

  9. REMOVE EXHAUST GAS TEMPERATURE SENSOR (w/ DPF)

    Click here

  10. REMOVE NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  11. REMOVE NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  12. REMOVE PIPE CLAMP (w/ DPF)

    Click here

  13. REMOVE ENGINE COVER BRACKET


    1. B0025PF

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

  14. REMOVE GAS FILTER

    Click here

  15. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  16. REMOVE EGR VALVE BRACKET

    Click here

  17. REMOVE NO. 2 EGR PIPE

    Click here

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

    Click here

  19. 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. 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.

  20. 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.

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


    1. B0069F2

      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. B0068JS

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

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

    Click here

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


    1. w/ DPF:


      1. B0028Z4C01
        *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
        *5 No. 17 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. Slide the clamp and disconnect the No. 17 water by-pass hose from the EGR pipe with cooler sub-assembly.

      5. for Cold Area Specification Vehicles:

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

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

    2. w/o DPF:


      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.

  24. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)


    1. B0025IQ

      Remove the 4 nuts, bolt and EGR pipe with cooler 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.

  25. 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

  26. 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.

  27. 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.

  28. 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.

  29. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  30. 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.

  31. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  32. REMOVE MANIFOLD STAY

    Click here

  33. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  34. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  35. REMOVE NO. 2 FUEL HOSE

    Click here

  36. REMOVE NO. 1 FUEL HOSE

    Click here

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

    Click here

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

    Click here

  39. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  40. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  41. REMOVE INTAKE MANIFOLD

    Click here

  42. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  43. REMOVE NO. 1 FUEL PIPE (w/ DPF)

    Click here

  44. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  45. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B0026T5

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

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

    Click here

  47. REMOVE COMMON RAIL ASSEMBLY

    Click here

  48. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  49. REMOVE GLOW PLUG ASSEMBLY

    Click here

  50. REMOVE HOSE BRACKET


    1. B0024IT

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

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


    1. B0026NZ

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

  52. 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.

  53. 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.

  54. 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.

  55. 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.

  56. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  57. REMOVE PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  58. 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.

  59. 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.

  60. REMOVE NO. 1 INJECTOR HOLDER (w/ DPF)

    Click here

  61. REMOVE AIR FUEL RATIO SENSOR (w/ DPF)

    Click here

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


  63. 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.

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


  65. 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.

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


  67. 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.

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


  69. 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.

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


  71. 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.

  72. REMOVE PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  73. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  74. 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.

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

    Click here

  76. 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.

  77. REMOVE TURBOCHARGER STAY

    Click here

  78. REMOVE TURBO OIL OUTLET PIPE

    Click here

  79. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  80. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  81. REMOVE EXHAUST MANIFOLD

    Click here

  82. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  83. 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.

  84. 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.

  85. REMOVE WATER INLET


    1. B0027R9

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

  86. REMOVE THERMOSTAT

    Click here

  87. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  88. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

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


    1. B0025B0C01
      *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.

  90. 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.

  91. 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.

  92. REMOVE VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  93. REMOVE CRANKSHAFT PULLEY COVER

    Click here

  94. REMOVE CRANKSHAFT PULLEY

    Click here

  95. 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.