ENGINE UNIT (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE GENERATOR ASSEMBLY


    1. A00JWXP

      Remove the 2 bolts and generator.

  2. REMOVE GENERATOR BRACKET


    1. A00JVLM

      Remove the bolt and generator bracket.

  3. REMOVE IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A00JXFL

      Remove the bolt, pulley plate, idle pulley and spacer.

  4. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A00JUTJ

      Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  5. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00JXLV

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  6. REMOVE NO. 1 FUEL PIPE


    1. A00K16AE01
      Text in Illustration
      *1 No. 2 Fuel Pipe

      Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

  7. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A00K1IA

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

  8. REMOVE TURBINE OUTLET ELBOW STAY


    1. A00JYXE

      Remove the 2 bolts and turbine outlet elbow stay.

  9. REMOVE NO. 2 TURBINE OUTLET ELBOW


    1. A00JTRW

      Remove the 3 nuts, No. 2 turbine outlet elbow and gasket.

  10. REMOVE FUEL PIPE CLAMP


    1. A00JVSM

      Remove the bolt and fuel pipe clamp.

  11. REMOVE NO. 11 WATER BY-PASS HOSE


    1. A00JWCX

      Disconnect the exhaust fuel addition injector connector.

    2. Remove the No. 11 water by-pass hose.

  12. REMOVE TURBINE OUTLET ELBOW


    1. A00JY22E01
      Text in Illustration
      *1 No. 4 Water By-pass Pipe
      *2 No. 12 Water By-pass Hose
      *3 Turbine Outlet Elbow
      *4 Gasket
      *5 Union Bolt

      Remove the union bolt and gasket from the turbine outlet elbow.

    2. Disconnect the No. 4 water by-pass pipe from the No. 12 water by-pass hose.

    3. Remove the 3 nuts, turbine outlet elbow and gasket.

  13. REMOVE VENTILATION PIPE


    1. A00JWRJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  14. REMOVE NO. 1 TURBO INSULATOR


    1. A00K0PW

      Remove the 2 bolts and No. 1 turbo insulator.

  15. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  16. DISCONNECT ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A00K1CV

      Remove the bolt.

    2. Disconnect the engine oil level dipstick guide.

  17. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A00K1L5E01
      Text in Illustration
      *1 No. 1 Turbo Water Hose
      *2 No. 3 Turbo Water Hose

      Disconnect the No. 1 turbo water hose from the No. 2 water by-pass pipe.

  18. DISCONNECT NO. 3 TURBO WATER HOSE


    1. Disconnect the No. 3 turbo water hose from the No. 2 water by-pass pipe.

  19. REMOVE TURBOCHARGER STAY


    1. A00JXIX

      Remove the 2 bolts, nut and turbocharger stay.

  20. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A00JTYE

      Remove the bolt and wire harness clamp bracket.

  21. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A00K21PE01

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.

      Note

      Do not loosen the nut labeled A in the illustration.

  22. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


    1. A00K02U

      Remove the 8 nuts and 8 plate washers from the exhaust manifold with turbocharger.

    2. Remove the exhaust manifold with turbocharger and gasket.

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A00JZFN

      Remove the bolt and engine oil level dipstick guide.

  24. REMOVE COMPRESSOR ELBOW STAY


    1. A00JZDU

      Remove the 3 bolts and compressor elbow stay.

  25. REMOVE NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A00K17M

      Disconnect the 3 hoses.

    2. Remove the 2 bolts, nut and No. 5 water by-pass pipe.

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


    1. A00JZK1

      Remove the bolt, nut and No. 2 water by-pass pipe.

  27. REMOVE NO. 2 ENGINE COVER BRACKET


    1. A00JWSS

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

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


    1. A00K067

      Disconnect the 2 vacuum hoses.

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

  29. REMOVE NO. 1 VACUUM PIPE


    1. A00JZWA

      Remove the bolt and No. 1 vacuum pipe.

  30. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A00JWNS

      Remove the No. 2 cylinder block insulator from the front No. 1 engine mounting bracket RH.

  31. REMOVE WATER INLET


    1. A00K21S

      Disconnect the connector and remove the 3 bolts and water inlet.

  32. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  33. REMOVE NO. 3 CYLINDER BLOCK INSULATOR


    1. A00JUXO

      Detach the clip and remove the No. 3 cylinder block insulator.

  34. REMOVE ENGINE OIL LEVEL SENSOR


    1. A00JYDI

      Remove the 4 bolts and engine oil level sensor.

    2. Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Tech Tips

      Remove only the outer part of the gasket.

  35. REMOVE VACUUM PUMP ASSEMBLY


    1. A00JWM7E01

      Remove the 2 nuts, vacuum pump and 2 O-rings.

  36. REMOVE VANE PUMP ASSEMBLY


    1. A00JX1D

      Remove the 2 nuts, vane pump and O-ring.

  37. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A0095Y6

      Disconnect the engine coolant temperature sensor connector.

    2. Remove the engine coolant temperature sensor.

    3. Remove the gasket from the engine coolant temperature sensor.

  38. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A00JYX1

      Remove the bolt and oil pressure switching valve.

  39. REMOVE CAMSHAFT POSITION SENSOR


    1. A00JVQX

      Remove the bolt and camshaft position sensor.

  40. REMOVE CRANKSHAFT POSITION SENSOR


    1. Disconnect the crankshaft position sensor connector.

    2. A00JYTWE01

      Remove the clamp labeled A in the illustration.

      Note


      • Make sure that no portion of the clamp labeled A remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

      • Do not reuse the clamp labeled A.

    3. Detach the 3 wire harness clamps and remove the bolt and crankshaft position sensor.

  41. REMOVE NO. 1 TIMING BELT COVER


    1. A0094PCE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  42. REMOVE TIMING BELT


    1. A0098L2E05
      Text in Illustration
      *1 Timing Mark

      Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A00960LE01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A0098I0E02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.

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

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  44. REMOVE CRANKSHAFT PULLEY


    1. A00JZE1E01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A00JYY4E01

      Using SST, remove the pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  45. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A00JV51

      Disconnect the throttle control motor connector.

    2. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  46. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A00JZBI

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  47. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A00JW2S

      Remove the bolt and emission control valve bracket.

  48. REMOVE THROTTLE BODY BRACKET


    1. A00K044

      Remove the 3 bolts and throttle body bracket.

  49. REMOVE NO. 1 GAS FILTER


    1. A00JZLL

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  50. REMOVE GAS FILTER BRACKET


    1. A00K1HA

      Detach the clamp and disconnect the wire harness.

    2. A00K059

      Remove the bolt and gas filter bracket.

  51. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XEDI

      Remove the 4 bolts and No. 2 cylinder head cover.

  52. REMOVE NO. 1 VACUUM TRANSMITTING PIPE


    1. A00JWCY

      Disconnect the vacuum hose from the intake manifold.

    2. Remove the bolt and No. 1 vacuum transmitting pipe.

  53. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A00K07S

      Disconnect the 3 vacuum switching valve connectors.

    2. A00JXQ8

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00JWWJ

      Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.

    4. A00K0R0

      Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    5. A00JZPM

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  54. REMOVE WATER BY-PASS HOSE


    1. Detach the 4 water by-pass hose clamps.

    2. Disconnect the No. 7 water by-pass hose labeled A in the illustration.

    3. Disconnect the No. 4 water by-pass hose labeled B in the illustration.

    4. Disconnect the No. 3 water by-pass hose labeled C in the illustration.

    5. Disconnect the No. 8 water by-pass hose labeled D in the illustration.

    6. Disconnect the No. 6 water by-pass hose labeled E in the illustration.

    7. Disconnect the No. 5 water by-pass hose labeled F in the illustration.

      A00JVKBE01

  55. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A00JY27

      Remove the bolt and No. 2 injection pipe clamp.

    2. A00JTVIE01
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  56. REMOVE WIRING HARNESS CLAMP BRACKET


    1. Disconnect the glow plug connector.

    2. A00JZIR

      Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.

    3. A00JXS6

      Remove the bolt and wiring harness clamp bracket.

  57. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

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


    1. A00JX3O

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A00JZI1

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

    3. A00JZZPE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  58. REMOVE AIR CONNECTOR STAY


    1. A00K23C

      Remove the 3 bolts and air connector stay.

  59. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER


    1. Remove the 2 nuts, the 5 bolts and the electric EGR control valve with No. 2 EGR valve and EGR cooler.

    2. Remove the 2 gaskets from the cylinder head and intake manifold.

      A00JUWM

  60. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A00JZA1

      Remove the 2 nuts, bolt and intake air connector together with the electric EGR control valve.

    2. Remove the electric EGR control valve and 2 gaskets from the intake air connector.

  61. REMOVE EGR VALVE ADAPTER


    1. A00JYFQ

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  62. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A00JXK2

      Remove the bolt, No. 2 EGR valve and gasket.

  63. REMOVE EGR COOLER INSULATOR


    1. A00JUYBE01
      Text in Illustration
      *1 No. 2 EGR Cooler Insulator
      *2 No. 1 EGR Cooler Insulator

      Remove the 2 EGR cooler insulators from the EGR cooler.

  64. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XCX9

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A00XCYIE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  65. REMOVE NO. 2 FUEL PIPE


    1. A00XIX4

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A00XHOQ Union Bolt
      A00XFQT Fuel Check Valve

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

  66. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A00XGZK

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A00XFQT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  67. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00XET4

      Remove the 3 bolts.

      Text in Illustration
      A00XFQT Union Bolt

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

  68. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the 2 vacuum switching valve connectors.

    2. A00JXLJ

      Disconnect the 3 vacuum hoses, and then remove the 2 bolts and vacuum control valve set.

  69. REMOVE INTAKE PIPE STAY


    1. A00K275

      Remove the bolt and intake pipe stay.

  70. REMOVE INTAKE MANIFOLD INSULATOR


    1. A00JUX8

      Remove the intake manifold insulator.

  71. REMOVE INTAKE MANIFOLD


    1. A00K0U5

      Detach the sensor wire connector clamp from the intake manifold.

    2. A00K1WP

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

  72. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. Disconnect the No. 1 glow plug connector from the wire harness.

    2. A00OAW4

      Remove the 4 screw grommets.

    3. A00O6O5

      Remove the 4 nuts and No. 1 glow plug connector.

  73. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A00O6UR

  74. REMOVE GLOW PLUG ASSEMBLY

    A00O9Z7

    1. Using a 12 mm deep socket wrench, remove the 4 glow plugs.

  75. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  76. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector.

    2. A00K0E5

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.

  77. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A00K1G2

      Remove the No. 2 intake manifold insulator.

  78. REMOVE INJECTION PUMP INSULATOR

    A00JU76

  79. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A00JY5C

      Remove the 2 bolts and No. 1 injection pump protector.

  80. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A00K1VXE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    3. A00JWI4E05

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    4. A00K1NZ

      Loosen the 2 nuts.

    5. A00JZAIE03

      Using SST, disconnect the fuel supply pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

  81. REMOVE WATER OUTLET


    1. A00JZQX

      Remove the 2 bolts, gasket and water outlet.

  82. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A00K14I

      Disconnect the vacuum hose.

    2. Remove the 2 nuts and No. 2 vacuum transmitting pipe.

  83. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. A00JYDO

      Remove the 13 bolts and oil cooler cover.

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


    1. A00JZ1E

      Remove the bolt, nut and No. 1 vacuum transmitting pipe.

  85. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. A00JZ70

      Remove the 4 bolts and No. 1 oil pan cover.

  86. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET


    1. A00K16BE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Remove the 8 bolts and 2 front No. 1 engine mounting brackets.