Click here

ENGINE ASSEMBLY REMOVAL

Click here
Click here Click here
Note:

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

Click here
  1. Click here

    RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. Click here

    PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).

  3. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable some systems need to be initialized after the cable is reconnected (Click here).

  4. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    (Click here)

  5. Click here

    REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)


    1. A015BEI

      Remove the 2 nuts and No. 1 engine cover.

  6. Click here

    REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 7 clips and upper radiator support seal.

  7. Click here

    REMOVE MAIN BATTERY

  8. Click here

    REMOVE SUB-BATTERY

  9. Click here

    REMOVE FRONT WHEEL

  10. Click here

    REMOVE HOOD SUB-ASSEMBLY


    1. A015AM6

      Remove the 2 hood stay bolts. Then disconnect the 2 hood supports.

      Note:

      • Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing.

      • Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks.

      • Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed.

      • Remove the hood support while supporting the hood by hand.

    2. Remove the 4 bolts and hood.

  11. Click here

    REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. A015DL0

      Remove the 3 bolts and screw.

    2. Loosen the clip and remove the front fender splash shield LH.

  12. Click here

    REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Remove the 3 bolts and 2 screws.

    2. Loosen the clip and remove the front fender splash shield RH.

  13. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  14. Click here

    REMOVE NO. 2 ENGINE UNDER COVER


    1. A015A78

      Remove the 2 bolts and No. 2 engine under cover.

  15. Click here

    REMOVE OIL PAN PROTECTOR ASSEMBLY


    1. Remove the 4 bolts and oil pan protector.

  16. Click here

    DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tip:

    Collect the coolant in a container and dispose of it according to the regulations in your area.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator reservoir cap to drain the coolant in the radiator.

    3. A015DKUE01

      Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      13 N*m 133 kgf*cm 10 ft.*lbf
  17. Click here

    DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. A0158R9

      Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Install a new gasket and the oil pan drain plug.

      38 N*m 387 kgf*cm 28 ft.*lbf
  18. Click here

    REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    (Click here)

  19. Click here

    REMOVE NO. 3 ENGINE ROOM WIRE


    1. Disconnect the 4 wire harness clamps.

    2. A0156P2

      Remove the 2 nuts and No. 3 engine room wire.

  20. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  21. Click here

    REMOVE AIR CLEANER FILTER ELEMENT

  22. Click here

    REMOVE AIR CLEANER CASE


    1. A015D2K

      Using a clip remover, detach the wire harness clamp.

    2. Remove the 3 bolts and air cleaner case.

  23. Click here

    REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

      Loosen the hose clamp and remove the No. 1 air cleaner hose.

  24. Click here

    REMOVE INTAKE AIR CONNECTOR


    1. A015852E04

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

      Table 1. Text in Illustration
      *A w/ Viscous Heater

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

    3. Using a clip remover, detach the 3 wire harness clamps.

    4. A015DJJ

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

  25. Click here

    REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A0155N2

      Insert a screwdriver between the reservoir and oil reservoir bracket, push the claw, and then disconnect the reservoir by pulling it upwards.

  26. Click here

    REMOVE NO. 1 OIL RESERVOIR BRACKET


    1. A0159Q4

      Remove the 2 bolts and bracket.

  27. Click here

    REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A015BUM

      Disconnect the 2 hoses.

    2. Remove the 3 bolts and radiator reservoir.

  28. Click here

    REMOVE VANE PUMP ASSEMBLY


  29. Click here

    DISCONNECT NO. 1 RADIATOR HOSE

  30. Click here

    DISCONNECT NO. 2 RADIATOR HOSE

  31. Click here

    REMOVE V-RIBBED BELT (w/ Viscous Heater)


    1. A0155TJ

      Loosen the lock nut and turn the bolt counterclockwise.

    2. Remove the V-ribbed belt.

  32. Click here

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


    1. A015A7A

      Remove the bolt, cover, No. 1 idler pulley and collar.

  33. Click here

    REMOVE NO. 3 IDLER PULLEY (w/ Viscous Heater)


    1. A015C7J

      Remove the nut and No. 3 idler pulley.

  34. Click here

    REMOVE V-RIBBED BELT


    1. A015CL0

      Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

  35. Click here

    REMOVE FRONT FENDER APRON SEAL FRONT RH


    1. A015AN4

      Remove the 3 clips and front fender apron seal front RH.

  36. Click here

    REMOVE FRONT FENDER APRON SEAL REAR RH


    1. A015D4I

      Remove the 4 clips and front fender apron seal rear RH.

  37. Click here

    REMOVE FRONT FENDER APRON SEAL FRONT LH


    1. A015BDJ

      w/o KDSS:

      Remove the 4 clips and front fender apron seal front LH.

    2. A015CC0

      w/ KDSS:

      Remove the 3 clips and front fender apron seal front LH.

  38. Click here

    REMOVE FRONT FENDER APRON SEAL REAR LH


    1. A0155AV

      Remove the 4 clips and front fender apron seal rear LH.

  39. Click here

    REMOVE OIL COOLER TUBE (for Automatic Transmission)


    1. A01572W

      Disconnect the inlet and outlet No. 1 oil cooler hose.

    2. A015CST

      Disconnect the inlet No. 2 and No. 3 oil cooler hoses.

    3. A015BIC

      Disconnect the inlet No. 4 oil cooler hose.

    4. A01566A

      Remove the 2 bolts and transmission oil cooler tube.

  40. Click here

    REMOVE FAN SHROUD WITH FAN


    1. A015CLN

      Loosen the 4 nuts holding the fluid coupling fan.

    2. A0159DG

      Remove the 2 bolts holding the fan shroud.

    3. A015B5D

      Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid coupling fan.

  41. Click here

    REMOVE FAN PULLEY

  42. Click here

    REMOVE FRONT BUMPER WINCH COVER (w/ Winch)


    1. A0156DU

      Detach the 2 claws.

    2. Detach the 3 guides and remove front bumper winch cover sub-assembly.

  43. Click here

    REMOVE RADIATOR GRILLE


    1. A0157G3E01

      Put protective tape around the radiator grille assembly.

      Table 2. Text in Illustration
      *1 Protective Tape

    2. Remove the 3 screws.

    3. Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

    4. w/ Wide View Front Monitor System:


      1. Disconnect the connector.

  44. Click here

    REMOVE FRONT BUMPER COVER

    Tip:

    For the front bumper cover with garnish, use the procedure described below.


    1. A0155QIE01

      Put protective tape around the front bumper cover.

      Table 3. Text in Illustration
      *1 Protective Tape - -
    2. A015DGIE01

      Using a T30 "TORX" socket, remove the 6 screws.

      Table 4. Text in Illustration
      *A LH Side *B RH Side

    3. Remove the 3 clips, 4 screws and 4 bolts.

    4. A0158BY

      Detach the 10 claws and remove the front bumper cover.

    5. w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:

      Disconnect the No. 4 engine room wire connector and remove the front bumper cover.

    6. A0159AB

      w/ Headlight Cleaner System:

      Disconnect the headlight cleaner hose and remove the front bumper cover.

  45. Click here

    REMOVE TRANSMISSION OIL COOLER AIR DUCT (for Automatic Transmission)


    1. A015809

      Remove the 4 bolts and oil cooler air duct.

  46. Click here

    DISCONNECT RADIATOR SIDE DEFLECTOR RH (for Manual Transmission)


    1. A0157WT

      Using a clip remover, remove the 4 clips, and remove the side deflector.

  47. Click here

    DISCONNECT RADIATOR SIDE DEFLECTOR LH


    1. A015B9X

      Using a clip remover, remove the 4 clips, and remove the side deflector.

  48. Click here

    REMOVE RADIATOR ASSEMBLY


    1. A015BK7

      Remove the 4 bolts and radiator.

  49. Click here

    DISCONNECT FRONT DIFFERENTIAL BREATHER TUBE

  50. Click here

    DISCONNECT FUEL TUBE


    1. w/ DPF:

      Disconnect the 2 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

    2. w/o DPF:

      Disconnect the 3 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

  51. Click here

    REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)


    1. A015E40

      Loosen the No. 1 air hose clamp.

    2. Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    3. A0158C6

      Remove the 3 nuts, bolt and No. 1 cool air inlet.

    4. Remove the gasket from the air tube RH.

  52. Click here

    REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015B0X

      Loosen the No. 2 air hose clamp.

    2. A015A93

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  53. Click here

    DISCONNECT WATER HOSE SUB-ASSEMBLY

    Table 5. Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater
  54. Click here

    REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156LC

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. A015C0GE01

      Disconnect the ventilation hose from the cylinder head cover RH.

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

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

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

  55. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  56. Click here

    REMOVE DIESEL THROTTLE BODY ASSEMBLY RH


    1. A0159VX

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  57. Click here

    DRAIN CLUTCH FLUID (for Manual Transmission)

  58. Click here

    REMOVE CLUTCH HOSE (for Manual Transmission)


    1. A015C2Z

      Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

      Note:

      • Do not bend or damage the flexible hose tubes.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

    2. Remove the 2 clips.

    3. A0159T9

      Remove the bolt and clutch hose.

  59. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  60. Click here

    REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. A015APM

      Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

      Note:

      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.

    2. A0155T9

      Remove the 2 bolts and tube connector to flexible hose tube.

  61. Click here

    REMOVE NO. 1 GAS FILTER


    1. A01591S

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  62. Click here

    REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. A0156KS

      for Manual Transmission:


      1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.

    2. A0157EZ

      Remove the 2 bolts and No. 3 intercooler support bracket.

  63. Click here

    REMOVE DIESEL THROTTLE BODY ASSEMBLY LH


    1. A015A91

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  64. Click here

    REMOVE NO. 1 AIR HOSE


    1. A0158SB

      Loosen the hose clamp and remove the No. 1 air hose.

  65. Click here

    REMOVE NO. 3 AIR TUBE


    1. A0159U8

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. A0155HD

      Remove the bolt and disconnect the wire harness bracket.

    4. A01572L

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  66. Click here

    REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. A0158LS

      Remove the bolt and No. 1 air tube.

    2. Remove the O-ring.

  67. Click here

    REMOVE NO. 2 AIR HOSE


    1. A0155DS

      Loosen the hose clamp and remove the No. 2 air hose.

  68. Click here

    REMOVE NO. 4 AIR TUBE


    1. A015A8F

      Remove the bolt and disconnect the suction hose.

    2. A015577

      Loosen the hose clamp and remove the bolt and No. 4 air tube.

  69. Click here

    REMOVE NO. 2 AIR TUBE ASSEMBLY


    1. A0159YQ

      Remove the bolt and No. 2 air tube.

    2. Remove the O-ring.

  70. Click here

    REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015AEL

      Disconnect the ventilation hose from the oil separator.

    2. Loosen the hose clamp.

    3. Remove the bolt and No. 2 air cleaner pipe.

  71. Click here

    REMOVE NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A015CNU

      Remove the bolt and disconnect the discharge hose from the cooler compressor.

    2. Remove the O-ring from the discharge hose.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  72. Click here

    REMOVE SUCTION HOSE SUB-ASSEMBLY


    1. A01562J

      Remove the bolt and disconnect the suction hose from the cooler compressor.

    2. Remove the O-ring from the suction hose.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  73. Click here

    REMOVE COOLER COMPRESSOR ASSEMBLY


    1. A015D5V

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 3 wire harness clamps.

    3. A01558S

      Remove the 4 bolts and cooler compressor.

  74. Click here

    REMOVE NO. 2 INTAKE AIR CONNECTOR PIPE


    1. A0159KE

      w/ Intercooler:

      Disconnect the vacuum hose.

    2. A0158T4

      Loosen the hose clamp, and remove the bolt and No. 2 intake air connector pipe.

  75. Click here

    REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    1. A0158HY

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

  76. Click here

    REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015D8F

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  77. Click here

    DISCONNECT FUEL HOSE


    1. A0159B1E01

      w/ DPF:

      Table 7. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
    2. A0159IIE01

      w/o DPF:

      Table 8. Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater
  78. Click here

    REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    1. A015DM6

      Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

  79. Click here

    REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. A0157IQE01

        Remove the 2 bolts and nut.

        Table 9. Text in Illustration
        *A w/ DPF *B w/o DPF

      2. w/ DPF:

        Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

      3. w/o DPF:

        Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

    2. w/o EGR System:


      1. A0157AC

        Remove the 2 bolts and nut.

      2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

  80. Click here

    DISCONNECT ENGINE WIRE


    1. LH Side:


      1. A0157O0E01

        w/ DPF:

        Disconnect the 7 connectors from the injector driver.

        Table 10. Text in Illustration
        *A w/ DPF
        *B w/o DPF

      2. w/o DPF:

        Disconnect the 4 connectors from the injector driver.

      3. Disconnect the 4 connectors and detach the wire harness holder from the relay block.

      4. Remove the bolt and disconnect the ground wire.

      5. Disconnect the wire harness from the wire harness clamp holder.

      6. A015BB9E01

        Remove the bolt and disconnect the ground wire from the body panel.

      7. Using a clip remover, detach the ground wire clamp labeled A from the relay block side.

      8. Disconnect the wire harness from the wire harness clamp holder labeled B.

      9. A0156SG

        Remove the nut and detach the generator positive (+) cable holder from the relay block.

      10. Disconnect the generator positive (+) cable from the 2 clamps.

      11. A015AFR

        Disconnect the 2 connectors.

      12. Using a clip remover, detach the 3 wire harness clamps.

      13. A015DZIE01

        for RHD:

        Disconnect the 4 connectors and detach the wire harness tab labeled A from the relay block.

      14. for RHD:

        Disconnect the ECM connector.

      15. for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      16. A015AYBE01

        Disconnect the 8 connectors.

        Table 11. Text in Illustration
        *A w/ DPF *B w/o DPF

      17. Remove the bolt and the engine wire harness bracket labeled B.

      18. Using a clip remover, detach the wire harness clamp labeled D.

      19. Remove the 2 bolts and disconnect the engine wire protector labeled A.

      20. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. A01585NE01

        for LHD:

        Disconnect the 4 connectors, and detach the wire harness holder from the relay block labeled A.

      2. for LHD:

        Disconnect the ECM connector.

      3. for LHD:

        Disconnect the wire harness from the wire harness clamp holder.

      4. A015AIHE01

        Disconnect the 7 connectors.

        Table 12. Text in Illustration
        *A w/ DPF *B w/o DPF

      5. Using a clip remover, detach the wire harness clamp.

      6. Remove the 3 bolts and disconnect the engine wire protector labeled A.

      7. Remove the bolt and the wire harness bracket labeled B.

      8. Remove the screw grommet, nut and the glow plug wire harness labeled C.

      9. A015CM3E01

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

        Table 13. Text in Illustration
        *A w/ DPF
        *B w/o DPF

      10. for RHD:

        Remove the bolt and wire harness clamp holder.

      11. A015DUG

        w/ Winch:

        Remove the bolt and disconnect the ground wire.

    3. Rear Side:


      1. A0157RZE01

        Using a clip remover, detach the wire harness clamp.

        Table 14. Text in Illustration
        *A w/ DPF
        *B w/o DPF

      2. Remove the 2 bolts and 2 ground wires labeled C.

      3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

      4. w/ DPF:

        Disconnect the 3 connectors.

      5. w/o DPF:

        Disconnect the connector.

      6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

  81. Click here

    REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Note:

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.


    1. A015D15

      Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

    2. Remove the bolt and No. 2 injection pipe clamp.

    3. Remove the union bolt and gasket.

    4. Remove the bolt, nut and No. 2 fuel pipe.

  82. Click here

    REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


    1. w/ EGR System:


      1. A0157JU

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.

      3. Remove the No. 6 injection pipe.

    2. w/o EGR System:


      1. A0159AO

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the nut and No. 2 injection pipe clamp.

      3. Remove the bolt and No. 6 injection pipe.

  83. Click here

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


    1. A01576L

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  84. Click here

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


    1. A015AL5

      Disconnect the 2 vacuum hoses.

    2. A0159QH

      Remove the 3 bolts and vacuum transmitting pipe.

  85. Click here

    REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)


    1. A015AO1

      Remove the 4 bolts and cylinder head cover silencer.

  86. Click here

    REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A01571T

      Disconnect the fuel hose.

    2. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

  87. Click here

    REMOVE INJECTION PIPE LH


    1. A015B4EE01

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

      Table 15. Text in Illustration
      *A w/ DPF
      *B w/o DPF
    2. A015E5OE01

      Using a union nut wrench, remove the 4 injection pipes.

      Table 16. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  88. Click here

    REMOVE NO. 2 FUEL PIPE (w/ DPF)


    1. A015CIM

      Remove the No. 4 fuel hose.

    2. Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

  89. Click here

    REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. A015E4L

        Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

    2. A0156LG

      w/o DPF:

      Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

  90. Click here

    REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01

      Remove the 2 bolts and common rail.

      Table 17. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

  91. Click here

    REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. w/ DPF:


      1. A015D39

        Remove the bolt and No. 2 injection pipe clamp.

      2. Disconnect the fuel hose.

      3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

    2. w/o DPF:


      1. A01588A

        Disconnect the 2 hoses from the fuel pipe.

      2. Remove the bolt and fuel filter to injection pump fuel pipe.

  92. Click here

    DISCONNECT FUEL PUMP MOTOR WIRE


    1. A0159T3

      Remove the bolt and disconnect the connector from the fuel supply pump.

  93. Click here

    REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY


    1. A0156FM

      Using a union nut wrench, remove the No. 5 injection pipe.

      Note:

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

  94. Click here

    REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)


    1. A015AD8

      Remove the 4 bolts and cylinder head cover silencer.

  95. Click here

    REMOVE INJECTION PIPE RH


    1. A0155GHE01

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

      Table 18. Text in Illustration
      *A w/ DPF
      *B w/o DPF
    2. A015B9WE01

      Using a union nut wrench, remove the 4 injection pipes.

      Table 19. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  96. Click here

    REMOVE COMMON RAIL ASSEMBLY RH


    1. A0157DVE01

      Remove the 2 bolts and common rail.

      Table 20. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

  97. Click here

    REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  98. Click here

    REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  99. Click here

    REMOVE CONNECTING WIRE (w/ DPF)


    1. A0158N3

      Detach the 2 clamps and remove the connecting wire.

  100. Click here

    REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A0155NQ

      Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

  101. Click here

    REMOVE INTAKE PIPE


    1. A01580H

      w/ EGR System:

      Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

    2. A015CFP

      w/o EGR System:

      Remove the 2 nuts, 4 bolts, intake pipe and gasket.

  102. Click here

    DISCONNECT NO. 2 ENGINE WIRE


    1. A0156MM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  103. Click here

    REMOVE NO. 3 INTAKE MANIFOLD


    1. A0158GX

      Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

  104. Click here

    REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

  105. Click here

    REMOVE EGR PIPE INSULATOR (w/ EGR System)


    1. A015B26

      Remove the 2 bolts and EGR pipe insulator.

  106. Click here

    REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    1. A01584Z

      Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

    2. A015AI2

      Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

  107. Click here

    REMOVE EGR COOLER INSULATOR (w/ EGR System)

  108. Click here

    REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. A015AB8

      Disconnect the No. 1 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

      Note:

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  109. Click here

    REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. A015AQI

      Disconnect the No. 2 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

      Note:

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  110. Click here

    DISCONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

  111. Click here

    REMOVE FUEL COOLER ASSEMBLY (w/o DPF)


    1. A0159DJ

      Remove the 2 bolts and fuel cooler.

  112. Click here

    REMOVE NO. 2 FUEL INJECTOR PROTECTOR (w/ DPF)


    1. A0156K1

      Detach the hose clamp.

    2. Remove the bolt and No. 2 fuel injector protector.

  113. Click here

    REMOVE NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)


    1. A0156CK

      Remove the bolt and No. 1 fuel injector protector.

  114. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)


    1. A0159VL

      Disconnect the 3 fuel tube connectors (Click here).

    2. Detach the 3 clamps and remove the fuel tube.

  115. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE


    1. A015B5OE01

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

      Table 21. Text in Illustration
      *A w/ DPF
      *B w/o DPF
  116. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A015BOU

      Remove the 4 injector hollow screws and 4 gaskets.

      Table 22. Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Bolt

    2. Remove the 2 bolts and No. 2 nozzle leakage pipe.

      Note:

      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  117. Click here

    REMOVE NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A0156JO

      Remove the 4 injector hollow screws and 4 gaskets.

      Table 23. Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 No. 2 Check Valve
      A0158FK Union Bolt

    2. Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

    3. Remove the union bolt and No. 1 nozzle leakage pipe.

      Note:

      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  118. Click here

    REMOVE FUEL HOSE BRACKET (w/ DPF)


    1. A015DU1

      Remove the bolt and fuel hose bracket.

  119. Click here

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


    1. A0159I1E01

      Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

      Table 24. Text in Illustration
      *a RH Side
      *b LH Side
  120. Click here

    REMOVE NO. 1 INTAKE MANIFOLD


    1. A0158DT

      Remove the 9 bolts, No. 1 intake manifold and gasket.

  121. Click here

    REMOVE NO. 2 INTAKE MANIFOLD


    1. A0157X0

      Remove the 9 bolts, No. 2 intake manifold and gasket.

  122. Click here

    INSTALL NO. 1 AND NO. 2 ENGINE HANGER


    1. A015AHRE02

      Install the No. 1 and No. 2 engine hangers to the cylinder head RH and LH with the 4 bolts as shown in the illustration.

      25 N*m 250 kgf*cm 18 ft.*lbf
      Tip:
      No. 1 engine hanger 12281-51040
      No. 2 engine hanger 12282-51040
      Bolt 91671-80825
      Table 25. Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *a RH
      *b LH
  123. Click here

    REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    (Click here)

  124. Click here

    REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    (Click here)

  125. Click here

    REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. A0159A9

      Remove the bolt and clutch release cylinder to flexible hose tube.

  126. Click here

    REMOVE ENGINE ASSEMBLY


    1. A0155PK

      Attach an engine sling device and hang the engine with a chain block.

    2. Remove the 4 bolts from the engine mounting RH and LH side.

    3. Lift the engine out of the vehicle carefully.

      Note:

      • Make sure the engine is clear of all wiring and hoses.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    4. Place the engine onto a work bench.

  127. Click here

    REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. Put matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 8 set bolts, and pull off the clutch cover.

      Note:

      Do not drop the clutch disc.

  128. Click here

    REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note:

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  129. Click here

    REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A015782

      Using a wrench, hold the crankshaft.

      Note:

      Do not turn the crankshaft counterclockwise.

      If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt (Click here).

      108 N*m 1101 kgf*cm 80 ft.*lbf or more
    2. A0157I7

      Remove the 8 bolts.

    3. A0158N2E01

      Remove the rear drive plate spacer labeled A, drive plate and ring gear labeled B and rear crankshaft balancer weight labeled C.

  130. Click here

    REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A015782

      Using a wrench, hold the crankshaft.

      Note:

      Do not turn the crankshaft counterclockwise.

      If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt (Click here).

      108 N*m 1101 kgf*cm 80 ft.*lbf or more
    2. A0155ES

      Remove the 8 bolts and flywheel.

  131. Click here

    INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with bolts.

    2. Remove the 4 bolts and No. 1 and No. 2 engine hangers.

  132. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. Disconnect the vacuum hose.

    2. Remove the nut and mounting insulator.

  133. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR LH


    1. A0156OA

      Remove the nut and mounting insulator.