ENGINE UNIT REMOVAL


  1. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)


    1. A0155AS

      Remove the 3 bolts and vacuum pump.

    2. Remove the 2 O-rings.

  2. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01578C

      Remove the 2 bolts and No. 1 engine oil level dipstick guide.

    2. Remove the O-ring from the No. 1 engine oil level dipstick.

  3. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE


    1. A015AXC

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 5 wire harness clamps.

    3. A015E2Z

      Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.

  4. REMOVE GENERATOR ASSEMBLY


    1. A015ABF

      Remove the nut and bolt, and disconnect the generator positive (+) cable.

    2. A015E66

      Remove the 3 bolts, 2 nuts and generator.

  5. REMOVE NO. 2 VENTILATION HOSE

    A0159XJE01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  6. REMOVE NO. 2 TURBO WATER HOSE

    A015C6G

  7. REMOVE BREATHER PLUG RH


    1. A015ATR

      Disconnect the hose.

    2. Detach the clamp and remove the breather plug RH.

  8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015DQXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

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

  9. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE

    A015952

  10. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01596N

      Disconnect the water hose.

    2. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.

  11. REMOVE NO. 1 TURBOCHARGER STAY


    1. A015AVN

      Remove the 2 bolts and No. 1 turbocharger stay.

  12. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY


    1. A0156CB

      Disconnect the hose.

    2. Remove the union bolt, bolt, No. 1 ventilation tube and gasket.

  13. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH


    1. A015B3D

      Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.

    2. Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.

      A015A4VE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    3. Remove the gasket.

    4. A015D0F

      w/ DPF:

      Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.

    5. Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.

      A0155TWE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    6. Remove the gasket from the No. 1 turbocharger.

  14. REMOVE NO. 3 VENTILATION HOSE

    A015CQ4E01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  15. REMOVE BREATHER PLUG LH


    1. A01562TE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the hose.

    2. w/o DPF:

      Detach the clamp.

    3. Remove the breather plug LH.

  16. REMOVE NO. 2 TURBO WATER HOSE

    A0157W9

  17. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015ASCE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  18. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015D12

      Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.

  19. REMOVE FRONT WATER BY-PASS JOINT


    1. A0157D8

      Remove the front water by-pass joint and gasket.

  20. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015C38

      Disconnect the water hose.

    2. Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.

  21. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE

    A0156TV

  22. REMOVE NO. 2 TURBOCHARGER STAY


    1. A015A3Y

      Remove the 2 bolts and No. 2 turbocharger stay.

  23. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY


    1. Disconnect the hose.

      A0155F8E01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Remove the union bolt, bolt, No. 2 ventilation tube and gasket.

  24. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH


    1. A0158JX

      Disconnect the 2 connectors from the turbocharger.

    2. A015674

      Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.

    3. Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.

      A015D0BE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    4. Remove the gasket.

    5. A015AVS

      w/ DPF:

      Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.

    6. A015BQJE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

    7. Remove the gasket from the turbocharger.

  25. REMOVE VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

    A01560B

    1. Disconnect the connector and detach the clamp.

    2. Using pliers, grip the claws of the clips and slide the 2 clips.

    3. Disconnect the 2 heater hoses.

    4. Remove the 2 bolts and heater assembly.

  26. REMOVE NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)


    1. A0155QF

      Remove the bolt and No. 1 idler pulley bracket.

  27. REMOVE WATER INLET


    1. A015CD1

      Disconnect the No. 2 oil cooler hose from the water pump and clamp.

    2. A015E4I

      Remove the 4 bolts and water inlet.

  28. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  29. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)


    1. A015B15

      w/o Viscous Heater:

      Remove the 2 bolts and timing gear cover insulator.

    2. A015BZO

      w/ Viscous Heater:

      Remove the timing gear cover insulator.

  30. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A015AA4

      Remove the 3 bolts and V-ribbed belt tensioner bracket.

    2. A0156FA

      Remove the bolt and No. 1 idler pulley.

    3. A01597P

      Remove the 5 bolts and V-ribbed belt tensioner.

  31. REMOVE STARTER ASSEMBLY


    1. A015DCB

      Detach the harness clamp and disconnect the wire harness.

    2. Disconnect the starter connector.

    3. Remove the nut and disconnect the starter wire.

    4. A015CX5

      Disconnect the 2 starter hoses.

    5. A0158Q9

      Remove the 2 bolts and starter.

  32. REMOVE STARTER HOSE BRACKET


    1. A015CPF

      Remove the 2 bolts and starter hose bracket.

  33. DISCONNECT INLET WATER HOSE

    A0156YW

  34. REMOVE DIESEL ENGINE COOLANT TEMPERATURE SENSOR

    A0159PT

    1. Disconnect the sensor connector.

    2. Using a 19 mm deep socket wrench, remove the sensor and gasket.

  35. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET


    1. A015BEV

      Remove the 2 bolts and No. 2 intercooler support bracket.

  36. REMOVE WATER OUTLET


    1. A015BNC

      Remove the 2 bolts and gasket and disconnect the water outlet from the No. 2 water hose joint.

  37. REMOVE WATER OUTLET PIPE


    1. A015BJ2

      Remove the 4 bolts, water outlet pipe and 2 gaskets.

  38. SEPARATE NO. 1 AND NO. 2 WATER OUTLET PIPES AND WATER BY-PASS OUTLET


    1. A015921

      Remove the 2 bolts and No. 1 water outlet pipe from the No. 2 water outlet pipe.

    2. A01598T

      Disconnect the No. 2 water outlet pipe from the No. 1 water hose joint.

    3. A015AEP

      Disconnect the water by-pass outlet from the No. 1 water hose joint.

  39. REMOVE CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. A0157L4

      Remove the 2 bolts and clutch flexible hose bracket.

  40. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. Remove the 2 screw grommets and 2 nuts, and disconnect the 2 wire harnesses.

    2. A015DN4E01
      Text in Illustration
      *a RH
      *b LH

      Remove the 8 screw grommets, 8 nuts and 2 glow plug connectors.

  41. REMOVE GLOW PLUG ASSEMBLY


    1. A01580TE01
      Text in Illustration
      *a RH
      *b LH

      Using a 10 mm deep socket wrench, remove the 8 glow plugs.

      Tech Tips

      Before removing the glow plugs, thoroughly clean off all dirt, sand, etc.

  42. REMOVE FUEL PUMP MOTOR WIRE


    1. A01556N

      Disconnect the 2 connectors and remove the bolt and fuel pump motor wire.

  43. REMOVE NO. 2 IDLER PULLEY (w/ Viscous Heater)


    1. A0159CU

      Remove the bolt, cover, No. 2 idler pulley and collar.

  44. REMOVE NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)


    1. A015C5N

      Remove the 3 bolts and idler pulley bracket.

  45. REMOVE FAN BRACKET SUB-ASSEMBLY


    1. A015AIZ

      Remove the 4 bolts and fan bracket.

  46. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/o DPF)


    1. A015COX

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  47. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o DPF)


    1. A015BP2

      w/ Intercooler:

      Disconnect the 2 vacuum hoses.

    2. A0159UD

      Remove the 3 bolts and vacuum transmitting pipe.

  48. REMOVE CYLINDER HEAD COVER SILENCER RH (w/o DPF)


    1. A015B6D

      w/ Intercooler:

      Remove the 3 bolts and cylinder head cover silencer RH.

  49. REMOVE CYLINDER HEAD COVER SILENCER LH (w/o DPF)


    1. A0158CR

      w/ Intercooler:

      Remove the 3 bolts and cylinder head cover silencer LH.

  50. REMOVE REAR CYLINDER HEAD PLATE RH (w/o EGR System)


    1. A015CM7

      Remove the 2 bolts, rear cylinder head plate RH and gasket.

  51. REMOVE REAR CYLINDER HEAD PLATE LH (w/o EGR System)


    1. A015CMI

      Remove the 2 bolts, rear cylinder head plate LH and gasket.

  52. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET


    1. A015DI3

      Remove the 2 bolts and No. 1 intake air connector bracket.

  53. REMOVE AIR TUBE SUPPORT


    1. A015AHS

      Remove the 2 bolts and air tube support.

  54. REMOVE NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A015CMG

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  55. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A0155EP

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 4 vacuum transmitting pipe.

  56. REMOVE ENGINE MOUNTING BRACKET RH


    1. A0158ZJ

      Remove the 4 bolts and engine mounting bracket RH.

  57. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    A015B29

  58. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A0155C7

      Detach the 2 wire harness clamps.

    2. A0157EH

      Remove the bolt and No. 2 intake air connector bracket.

  59. REMOVE TURBOCHARGER WIRE


    1. A015787

      Detach the 3 wire harness clamps.

    2. Remove the 2 bolts and turbocharger wire.

  60. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01578D

      w/ Intercooler:

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe.

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


    1. A015CRL

      Remove the union bolt, 2 bolts, No. 2 water by-pass pipe and gasket.

  62. REMOVE ENGINE MOUNTING BRACKET LH


    1. A015CB7

      Remove the 4 bolts and engine mounting bracket LH.

  63. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    A015BW0

  64. REMOVE OIL TANK BRACKET


    1. A015BA0

      Remove the bolt and oil tank bracket.

  65. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET


    1. A01594O

      Remove the 2 bolts and No. 1 intercooler support bracket.

  66. REMOVE NO. 3 ENGINE HANGER


    1. A0155SE

      Remove the 2 bolts and No. 3 engine hanger.

  67. REMOVE OIL FILTER BRACKET DRAIN COCK ASSEMBLY


    1. A0158UW

      Remove the oil filter drain cock plug.

    2. A01572T

      Remove the oil filter drain cock body.

      Tech Tips

      If the drain cock is deformed or clogged, replace or repair it.

  68. REMOVE OIL PRESSURE REGULATOR ASSEMBLY


    1. A015C1R

      Using a 26 mm wrench, remove the oil pressure regulator and gasket.

    2. Remove the O-ring from the oil pressure regulator body.

    3. Hold the oil pressure regulator body in a vise between aluminum plates.

      Note

      Be careful not to damage the oil pressure regulator body.

    4. A015AOOE01

      Using a 10 mm hexagon wrench, remove the oil pump relief valve plug labeled A and gasket.

      CAUTION:

      When removing the plug, be careful as the spring will be jumped out.

    5. Remove the 2 springs labeled B.

    6. Remove the oil pump relief valve labeled C.

  69. REMOVE STIFFENER INSULATOR RH (w/ Intercooler)


    1. A0156XQ

      Remove the 2 bolts and stiffener insulator RH.

  70. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01570BE02
      Text in Illustration
      *1 Timing Mark

      Align the timing mark of the crankshaft pulley and the chain cover and compressor bracket.

  71. REMOVE COMPRESSOR BRACKET


    1. A015BRQ

      Remove the bolt and compressor bracket.

  72. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (w/ DPF)


    1. A0156BHE01
      Text in Illustration
      *A for Bank 1
      *B for Bank 2

      Disconnect the 2 exhaust fuel addition injector connectors.

    2. A015D22E01
      Text in Illustration
      *A for Bank 1
      *B for Bank 2
      *1 Washer
      *2 Nozzle Holder Clamp

      Remove the 2 bolts, 2 washers and 2 nozzle holder clamps.

    3. Remove the 2 exhaust fuel addition injectors and 2 gaskets.

  73. REMOVE FUEL INJECTOR SEAL (w/ DPF)


    1. A015B4VE01
      Text in Illustration
      *1 Fuel Injector Seal

      Remove the 2 fuel injector seals.

  74. REPLACE FLYWHEEL RING GEAR

    CAUTION:

    A0159OAE01

    When torching the flywheel:


    • Wear protective gloves.

    • Be careful as the flywheel is hot.

    Tech Tips

    If the flywheel ring gear is deformed or the gear teeth are damaged, replace it.


    1. Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

    2. Install 8 10 mm x 1.25 pitch bolts with a length of 70 mm or more to the flywheel.

    3. Uniformly tighten the 8 bolts in the order shown in the illustration.

    4. Remove the ring gear from the flywheel.

    5. A015CQNE02
      Text in Illustration
      *a No Clearance

      Using a torch, heat a new ring gear evenly to approximately 200°C (392°F).

      Note

      Be careful not to overheat the ring gear.

    6. Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.

      Note


      • Make sure to press in the ring gear until the ring gear contacts the flywheel, as shown in A in the illustration.

      • After installing, allow the ring gear to cool before handling.

  75. REPLACE FLYWHEEL STRAIGHT PIN

    Tech Tips

    It is not necessary to remove the straight pin unless it is being replaced.


    1. Replace the flywheel straight pin.