ENGINE UNIT (w/o DPF) REMOVAL


  1. REMOVE GENERATOR ASSEMBLY


    1. A00K0CA

      Remove the 2 bolts and generator.

  2. REMOVE GENERATOR BRACKET


    1. A00JWMI

      Remove the bolt and generator bracket.

  3. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00K11Y

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

  4. REMOVE VENTILATION PIPE


    1. A00O8AJ

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

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00OB7F

      Remove the 2 bolts and engine oil level dipstick guide.

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

  6. REMOVE COMPRESSOR INLET ELBOW


    1. A00O4ML

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A00O913

      Disconnect the 2 connectors and detach the wire harness clamp.

    4. Disconnect the No. 2 turbo water hose and No. 3 turbo water hose.

    5. Remove the 2 nuts, compressor inlet elbow and gasket.

  7. REMOVE NO. 1 TURBO INSULATOR


    1. A00O8SA

      Remove the 2 bolts and No. 1 turbo insulator.

  8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Remove the bolt and No. 1 exhaust manifold heat insulator.

  9. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A00O5ZE

      Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe.

  10. REMOVE TURBINE OUTLET ELBOW


    1. A00O4V4

      Remove the 3 nuts, turbine outlet elbow and gasket.

  11. REMOVE TURBOCHARGER STAY


    1. A00O8QI

      Remove the 2 bolts, nut and turbocharger stay.

  12. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A00O3YYE01

      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.

  13. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


    1. A00OAOF

      Remove the 8 nuts, 8 plate washers and 8 collars from the exhaust manifold.

    2. Remove the exhaust manifold with turbocharger and gasket.

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


    1. A00JXED

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

  15. REMOVE COMPRESSOR ELBOW STAY


    1. A00JYP7

      Remove the 2 bolts and compressor elbow stay.

  16. REMOVE WATER INLET


    1. A00JVQC

      Remove the 3 bolts and water inlet.

  17. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

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


    1. A00JX4T

      Disconnect the 2 hoses.

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

  19. REMOVE ENGINE OIL LEVEL SENSOR


    1. A00K246

      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.

  20. REMOVE TIMING GEAR COVER INSULATOR


    1. A00JUUI

      Remove the bolt and gear cover insulator.

  21. REMOVE VACUUM PUMP ASSEMBLY


    1. A00JWM7E01

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

  22. REMOVE VANE PUMP ASSEMBLY


    1. A00JX1D

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

  23. 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.

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. A00JVQX

      Remove the bolt and camshaft position sensor.

  25. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00JUJI

      Detach the clamp and remove the bolt and crankshaft position sensor.

  26. REMOVE NO. 1 TIMING BELT COVER


    1. A0094PCE01

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

  27. 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.

  28. 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.

  29. 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 )

  30. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. A00O5VY

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  31. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  32. REMOVE INJECTION PIPE (w/ EGR System)

    Note


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

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


    1. A00OABQ

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

    2. A00O7DG

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

    3. A00O5DME01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  33. REMOVE AIR CONNECTOR STAY (w/ EGR System)


    1. A00OBBG

      Remove the 3 bolts and air connector stay.

  34. REMOVE EGR VALVE BRACKET (w/ EGR System)


    1. Remove the 2 nuts and EGR valve bracket.

  35. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)


    1. A00O80I

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. A00OBI1

      Detach the wire harness clamp.

    3. A00O7TG

      Disconnect the 5 vacuum hoses.

    4. Remove the bolt and gas filter together with the gas filter bracket.

    5. A00OAZB

      Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.

  36. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR System)


    1. A00O5AR

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  37. REMOVE INTAKE AIR CONNECTOR (w/ EGR System)


    1. A00O5UZ

      Remove the 3 bolts, intake air connector and 2 gaskets.

  38. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR System with EGR Cooler)


    1. A00O9MU

      Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.

    2. A00O8J1

      Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  39. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)


    1. A00OB8D

      Remove the 2 nuts and electric EGR control valve together with the No. 1 EGR pipe and gasket.

  40. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. A00O45CE01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 2 bolts, electric EGR control valve and gasket.

  41. REMOVE EGR VALVE ADAPTER (w/ EGR System with EGR Cooler)


    1. A00O3K9

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

  42. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)


    1. A00O4MP

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.

  43. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A00JWE0

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  44. REMOVE INJECTION PIPE (w/o EGR System)

    Note


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

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


    1. A00OABQ

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

    2. A00O7DG

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

    3. A00O5DME01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  45. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A00JUNJ

      Remove the 3 bolts and air connector stay.

  46. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/o EGR System)


    1. A00K0I0

      Remove the 3 nuts.

    2. Remove the No. 2 intake air connector, No. 1 intake air connector and 2 gaskets.

  47. REMOVE INTAKE AIR CONNECTOR (w/o EGR System)


    1. A00K0DN

      Remove the 3 bolts, intake air connector and gasket.

  48. REMOVE NO. 2 EGR HOLE COVER PLATE (w/o EGR System)


    1. A00K1U0

      Remove the 2 nut, gasket and No. 2 EGR hole cover plate.

  49. REMOVE WATER OUTLET


    1. A00JZQX

      Remove the 2 bolts, gasket and water outlet.

  50. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A00JYZ7

      Remove the 4 screw grommets, 4 nuts and No. 1 glow plug connector.

  51. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A00JYQC

      Remove the No. 1 intake manifold insulator.

  52. REMOVE GLOW PLUG ASSEMBLY


    1. A00JZBY

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

  53. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A00JVTA

      Disconnect the No. 1 vacuum transmitting hose.

    2. A00JXNI

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose assembly.

    3. A00JU6D

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    4. A00JU8HE01
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose assembly and No. 4 vacuum transmitting hose assembly.

    5. A00JVRB

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

  54. REMOVE INTAKE PIPE STAY


    1. A00O6BP

      Remove the bolt and intake pipe stay.

  55. REMOVE VACUUM CONTROL VALVE SET


    1. A00O7ZB

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  56. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XF0Y

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A00XHHME06
      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. 4 injection pipe.

  57. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00O7AGE01
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

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

  58. REMOVE INTAKE MANIFOLD INSULATOR


    1. A00O65M

      Remove the 2 bolts and intake manifold insulator.

  59. REMOVE INTAKE MANIFOLD


    1. A00O80CE01
      Text in Illustration
      *1 Sensor Wire

      Detach the sensor wire connector clamp from the intake manifold.

    2. A00O6FK

      Disconnect the vacuum hose from the intake manifold.

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

  60. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A00JY4V

      Remove the No. 2 intake manifold insulator.

  61. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A00JZ4Y

      Loosen the union nuts and remove the fuel inlet pipe.

  62. REMOVE COMMON RAIL ASSEMBLY


    1. A00JW0H

      Remove the 2 bolts and common rail.

      Note

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

  63. REMOVE 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 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 supply pump.

      Note


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

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

  64. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A00JYMZ

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

  65. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

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


    1. A00JV49

      Disconnect the vacuum hose.

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

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


    1. A00JXHD

      Disconnect the vacuum hose.

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

  68. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. A00JX2H

      Remove the 13 bolts and oil cooler cover.

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


    1. A00JWRB

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

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


    1. A00JZ70

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

  71. REMOVE NO. 1 VACUUM PIPE


    1. A00K1V1

      Remove the bolt and No. 1 vacuum pipe.

  72. REMOVE NO. 2 CYLINDER BLOCK INSULATOR


    1. A00JWNS

      Remove the No. 2 cylinder block insulator.

  73. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


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

      Remove the 8 bolts and 2 engine mounting brackets.