БЛОК ДВИГАТЕЛЯ СНЯТИЕ

REMOVE FAN AND GENERATOR V BELT

1. 

   Rotate the pulley of the V-ribbed belt tensioner assembly clockwise to loosen the fan and generator V belt and reduce the tension. Then remove the fan and generator V belt.

   Table 1. Text in Illustration

   *A	w/ Air Conditioning System
   *B	w/o Air Conditioning System

REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

1. 

   Отсоедините разъем и зажим жгута проводов.

2. Выверните болт, отверните 2 гайки и снимите компрессор в сборе со шкивом.

3. 

   С помощью торцевого ключа TORX E8 выверните 2 резьбовые шпильки.

4. Снимите штифт компрессора.

   Note:

   Снимать штифт компрессора нужно только в случае его замены.

REMOVE GENERATOR ASSEMBLY

1. 

   Отсоедините разъем генератора.

2. Снимите заглушку контакта.

3. Отверните гайку и отсоедините провод генератора.

4. 

   С помощью торцевого ключа "TORX" E12 выверните 2 болта, как показано на рисунке.

   Tip:

   Когда генератор в сборе установлен на автомобиле, болт A вывернуть нельзя.

5. 

   Снимите генератор в сборе, как показано на рисунке.

REMOVE DIESEL THROTTLE BODY ASSEMBLY

1. 

   Detach the water by-pass hose assembly and radiator hose sub-assembly from the air tube assembly.

2. 

   Disconnect the intake air temperature sensor connector.

3. 

   Disconnect the No. 7 engine wire connector and detach the clamp.

4. 

   Using a T27 "TORX" socket wrench, remove the bolt and disconnect the air tube assembly from the cylinder block sub-assembly.

5. 

   Using an E8 "TORX" socket wrench, remove the 3 bolts and diesel throttle body assembly with air tube assembly and gasket.

6. Detach the 2 claws and remove the air tube assembly from the diesel throttle body assembly.

7. Remove the gasket from the air tube assembly.

8. 

   Disconnect the diesel throttle body assembly connector.

REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

1. Remove the engine oil level dipstick.

2. 

   Detach the clamp and disconnect the fuel feed pipe sub-assembly from the engine oil level dipstick guide.

3. Using a T25 "TORX" socket wrench, remove the bolt and engine oil level dipstick guide.

4. Remove the O-ring from the engine oil level dipstick guide.

DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY

1. 

   Disconnect the No. 2 vacuum hose assembly from the No. 1 vacuum pipe.

   Table 2. Text in Illustration

   *1	No. 1 Vacuum Pipe

   
   

   1. Check that there is no damage or foreign matter on the part of the No. 1 vacuum pipe that contacts the No. 2 vacuum hose assembly connector.

   2. 

      If the No. 2 vacuum hose assembly connector and No. 1 vacuum pipe are stuck together, hold the No. 1 vacuum pipe by hand and push and pull on the No. 2 vacuum hose assembly connector.

      Table 3. Text in Illustration

      *1	Retainer
      	Pinch
      	Pull Out

      Note:
      

      • Check for any dirt and foreign matter contamination in the No. 1 vacuum pipe and around the No. 2 vacuum hose assembly connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

      • Do not use any tools to separate the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

      • Check for any dirt and foreign matter on the No. 1 vacuum pipe seal surface. Clean if necessary.

      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the No. 2 vacuum hose assembly.

      • If the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector are stuck together, pinch the No. 2 vacuum hose assembly connector between your fingers and turn it carefully to free it. Then disconnect the No. 2 vacuum hose assembly.

   3. Check for dirt or mud on the No. 1 vacuum pipe seal surface of the disconnected No. 1 vacuum pipe. Clean if necessary.

   4. To protect the disconnected No. 1 vacuum pipe and No. 2 vacuum hose assembly connector from damage and contamination, cover them with a plastic bag and tape.

REMOVE NO. 1 VACUUM PIPE

1. 

   Disconnect the vacuum hose.

2. Using an E7 "TORX" socket wrench, remove the bolt and No. 1 vacuum pipe from the cylinder block sub-assembly.

3. Remove the O-ring from the No. 1 vacuum pipe.

REMOVE INTAKE MANIFOLD

1. 

   Remove the bolt labeled B and loosen the 6 bolts labeled A in the order shown in the illustration, and then remove the intake manifold.

   Table 4. Text in Illustration

   	Bolt A
   	Bolt B

   Tip:

   The bolts labeled A in the illustration cannot be removed from the intake manifold.

2. 

   Remove the 4 gaskets from the intake manifold.

3. Remove the gasket from the No. 2 EGR pipe sub-assembly.

REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

1. 

   Detach the 2 clamps and disconnect the engine wire.

2. Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

1. 

   Remove the 2 bolts, 2 nuts and manifold stay.

2. 

   Loosen the V-band clamp.

3. 

   Remove the 3 nuts, 3 bolts, V-band clamp, gasket, engine bracket and exhaust manifold converter sub-assembly.

   Table 5. Text in Illustration

   *1	Engine Bracket	*2	Exhaust Manifold Converter Sub-assembly
   *3	No. 2 Manifold Stay	-	-

REMOVE TURBO OIL OUTLET PIPE

1. 

   Remove the 3 bolts, turbo oil outlet pipe and gasket.

2. Remove the O-ring from the turbo oil outlet pipe.

DISCONNECT NO. 1 TURBO OIL PIPE

1. 

   Remove the union bolt and 2 gaskets and disconnect the No. 1 turbo oil pipe.

REMOVE TURBOCHARGER SUB-ASSEMBLY

1. 

   Disconnect the connector from the turbocharger sub-assembly.

2. Remove the 4 bolts, turbocharger sub-assembly and gasket.

REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

1. 

   Disconnect the EGR valve assembly connector.

2. Detach the clamp and disconnect the engine wire from the EGR valve assembly.

3. Disconnect the hose clamp from the EGR cooler hose.

4. 

   Disconnect the vacuum hose from the EGR cooler assembly.

5. 

   Remove the 7 bolts and EGR cooler assembly with EGR valve assembly.

   Tip:
   

   • When removing the bolts labeled A, use a T45 "TORX" socket wrench.

   • When removing the bolts labeled B, use a 6 mm hexagon wrench.

   • The bolt labeled C in the illustration cannot be removed from the intake manifold.

6. Remove the gasket.

7. 

   Remove the water pipe from the EGR cooler assembly.

REMOVE EXHAUST MANIFOLD

1. 

   Remove the 8 nuts and exhaust manifold.

2. Remove the 2 gaskets from the cylinder head sub-assembly.

REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

1. 

   Using SST, loosen the union nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

   SST
   PZ4TB-04959-10

   Table 6. Text in Illustration

   *1	Rubber Grommet
   *2	Rubber Mount

   Note:

   Reset SST in a timely manner to prevent bending of pressure lines.

2. Using SST, loosen the union nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

   SST
   PZ4TB-04959-10

   Note:

   Reset SST in a timely manner to prevent bending of pressure lines.

3. Remove the fuel inlet pipe sub-assembly from the rubber grommet and rubber mount.

REMOVE COMMON RAIL ASSEMBLY

1. 

   Disconnect the fuel pressure sensor connector.

2. 

   Disconnect the pressure discharge valve connector.

3. 

   Push at the location shown in the illustration and disconnect the fuel return tube.

   Table 7. Text in Illustration

   *a

   Push

4. 

   Using an E10 "TORX" socket wrench, remove the 4 bolts and 2 common rail assembly brackets.

5. Remove the common rail assembly from the cylinder head cover sub-assembly.

REMOVE GLOW PLUG ASSEMBLY

1. Disconnect the 4 connectors from the glow plug assemblies.

2. 

   Using SST, remove the 4 glow plug assemblies.

   SST
   PZ4TB-04910-68

REMOVE EGR BYPASS VALVE SWITCHING VALVE ASSEMBLY

1. 

   Disconnect the EGR bypass valve switching valve assembly connector.

   
   

   1. Pull the EGR bypass valve switching valve assembly connector off of the EGR bypass valve switching valve assembly while pushing down the spring lock of the EGR bypass valve switching valve assembly connector.

      Table 8. Text in Illustration

      *a	Spring Lock

      Note:

      If the EGR bypass valve switching valve assembly connector is disconnected without the spring lock being pushed down, the EGR bypass valve switching valve assembly connector may be damaged.

2. Disconnect the 2 vacuum hoses.

3. Detach the claw and remove the EGR bypass valve switching valve assembly.

REMOVE VACUUM CONTROL VALVE BRACKET

1. 

   Disconnect the exhaust gas temperature sensor connector.

2. Detach the wire harness clamp.

3. 

   Disconnect the exhaust gas temperature sensor connector.

   Table 9. Text in Illustration

   *a	Air Fuel Ratio Sensor Connector
   *b	Exhaust Gas Temperature Sensor Connector
   *c	Clamp

4. Disconnect the air fuel ratio sensor connector.

5. Raise the air fuel ratio sensor connector from the vacuum control valve bracket.

6. Move the clamp as shown in the illustration, and disconnect the air fuel ratio sensor and exhaust gas temperature sensor.

   Note:

   Disconnect the sensors while opening the clamp.

7. Detach the air fuel ratio sensor clamp from the vacuum control valve bracket.

8. 

   Using a T20 "TORX" socket wrench, remove the 3 screws and disconnect the vacuum control valve bracket.