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, 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. REMOVE NO. 1 TIMING BELT COVER

    Click here

  2. REMOVE TIMING BELT

    Click here

  3. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  4. REMOVE CRANKSHAFT PULLEY SUB-ASSEMBLY

    Click here

  5. REMOVE VENTILATION HOSE HEAT INSULATOR


    1. Remove the 2 bolts and ventilation hose heat insulator from the cylinder head sub-assembly.

  6. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  7. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

    Click here

  8. REMOVE GENERATOR ASSEMBLY

    Click here

  9. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B0027IJ

      Remove the 4 bolts and V-ribbed belt tensioner assembly from the cylinder block sub-assembly.

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Remove the 4 bolts and No. 1 compressor mounting bracket from the cylinder block sub-assembly.

  12. REMOVE WATER INLET

    Click here

  13. REMOVE THERMOSTAT

    Click here

  14. REMOVE WATER OUTLET


    1. B0028AX

      Remove the 2 bolts, water outlet and gasket from the cylinder head sub-assembly.

  15. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  16. REMOVE INTAKE MANIFOLD

    Click here

  17. REMOVE NO. 2 EGR HOLE COVER PLATE


    1. Remove the 2 nuts and No. 2 EGR hole cover plate.

    2. Remove the gasket.

  18. REMOVE GLOW PLUG ASSEMBLY

    Click here

  19. REMOVE COMMON RAIL ASSEMBLY

    Click here

  20. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY

    Click here

  21. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    Click here

  22. REMOVE VACUUM PUMP ASSEMBLY


    1. B0026MB

      Remove the 2 nuts, vacuum pump assembly and 2 O-rings from the timing gear cover.

  23. REMOVE VANE PUMP ASSEMBLY


    1. B00293K

      Remove the 2 nuts, vane pump assembly and O-ring from the timing gear case assembly.

  24. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  25. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  26. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  27. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. B00263NC01
      *a LH Side
      *b RH Side

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  28. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Remove the 4 bolts and front No. 1 engine mounting bracket LH from th cylinder block sub-assembly.