БЛОК ДВИГАТЕЛЯ СНЯТИЕ


  1. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00K0NWE01

      Remove the 4 bolts and compressor mounting bracket.

  2. REMOVE CRANKSHAFT PULLEY

    A00JYNOE02
    Text in Illustration
    *a Hold
    *b Turn

    1. Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00JVDXE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      09950-60010   ( 09951-00490 )
      09950-40011   ( 09957-04010 )

  3. REMOVE TIMING BELT COVER


    1. A00JXCM

      Remove the 11 bolts, washers, timing belt cover, and 2 gaskets.

  4. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00K232E03
      Text in Illustration
      *1 Timing Mark
      A00JWY4 Turn

      Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

    2. A00JY76E02
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks of the camshaft timing pulley and No. 2 timing belt cover are aligned.

      If not, turn the crankshaft 1 revolution (360°).

  5. REMOVE TIMING BELT

    Tech Tips

    If reusing the timing belt, draw a direction arrow on the timing belt (in the direction the belt move when the engine is running), and place matchmarks on the pulleys and timing belt.


    1. A00JV64

      Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

      Text in Illustration
      A00JWY4 Turn

      Note

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, and camshaft causing damage. Therefore, always set the crankshaft pulley is removed at the correct angle.

    2. A00JZURE02

      Loosen the No. 1 timing belt idler bolt (A), and shift the idler to the left as far as possible.

      Text in Illustration
      A00JWY4 Pry
      A00JYOS Move

    3. Tighten the No. 1 timing belt idler bolt (A), and then relieve the timing belt tension.

    4. Remove the timing belt.

  6. REMOVE CRANKSHAFT TIMING PULLEY


    1. A00JZ4VE02

      Using a screwdriver, remove the crankshaft timing pulley.

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

      Tech Tips

      If the timing pulley cannot be removed by using a screwdriver, remove it with SST.

  7. REMOVE INTAKE FLANGE


    1. A009747

      Remove the bolt and disconnect the PCV hose and heater hose bracket.

    2. A009A45

      Disconnect the manifold absolute pressure sensor connector.

    3. A0095KM

      Remove the 3 nuts, intake flange and gasket.

  8. REMOVE DIESEL THROTTLE BODY


    1. A00979C

      Disconnect the throttle open switch connector.

    2. Remove the 2 bolts and disconnect the wire harness bracket.

    3. A00947WE02

      Disconnect the throttle control motor connector.

    4. Remove the diesel throttle body and gasket.

  9. REMOVE INJECTION PIPE SET


    1. A00JY0JE03
      Text in Illustration
      *1 Union Nut Wrench
      *a for Injection Nozzle Side
      *b for Injection Pump Side

      Using a union nut wrench, loosen the 8 union nuts of the 4 injection pipes.

    2. Remove the 2 nuts, 2 upper pipe clamps and 4 injection pipes with 2 lower pipe clamps.

  10. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A00JTSS

      Remove the nut, No. 2 glow plug resistor insulator and washer and disconnect the wire harness.

    2. Remove the 4 screw grommets and 4 nuts.

    3. Remove the No. 1 glow plug connector and No. 1 glow plug resistor insulator.

  11. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00JV8C

      Disconnect the fuel hose from the leakage pipe.

    2. Remove the 4 nuts, leakage pipe and 4 ring packing washers.

  12. REMOVE NOZZLE HOLDER & NOZZLE SET


    1. A00JX41E01

      Using SST, remove the 4 injection nozzles, 4 injection nozzle seats and 4 injection nozzle seat gaskets.

      SST
      09268-64010   ( 09268-64020 )

  13. REMOVE GLOW PLUG ASSEMBLY


    1. A00K050

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

  14. REMOVE INJECTION PUMP DRIVE PULLEY


    1. A00K1PUE01

      Using SST, remove the pulley nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
    2. A00JTPFE01

      Using SST, remove the drive pulley.

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

  15. REMOVE INJECTION PUMP ASSEMBLY


    1. A00JTZI

      Disconnect the 5 connectors and detach the wire harness clamp.

    2. Disconnect the 3 fuel hoses.

    3. A00JX2I

      Remove the 3 bolts and injection pump stay.

    4. Remove the 2 nuts and injection pump.

  16. REMOVE CRANK POSITION SENSOR


    1. A009B0Z

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  17. REMOVE WATER OUTLET HOUSING


    1. A00JZLG

      Remove the 3 bolts, outlet housing and gasket.

  18. REMOVE INTAKE MANIFOLD


    1. A00JYIM

      Remove the 6 bolts, 2 nuts, intake manifold and gasket.

  19. REMOVE WATER BY-PASS HOSE UNION


    1. Remove the water by-pass hose union.

  20. REMOVE NO. 1 GENERATOR BRACKET


    1. A00JUX7

      Remove the 3 bolts and No. 1 generator bracket.

  21. REMOVE PUMP BRACKET


    1. A00JVPH

      Remove the 3 bolts and pump bracket.

  22. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the dipstick.

    2. A00JWDK

      Remove the 2 bolts and dipstick guide.

    3. Remove the O-ring from the dipstick guide.

  23. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. A00JU60

      Remove the 4 bolts and engine mounting bracket.

  24. REMOVE VACUUM PUMP OIL INLET HOSE


    1. A00JWVQ

      Remove the union bolt and gasket, and then disconnect the vacuum pump oil inlet hose from the cylinder block.

  25. REMOVE UNION


    1. A00JUTC

      Remove the union from the cylinder block.

  26. REMOVE VACUUM PUMP OIL OUTLET HOSE


    1. A00JUT4

      Remove the bolt, 2 gaskets and vacuum pump outlet hose.

  27. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A00JYS8

      Remove the 4 bolts and engine mounting bracket.

  28. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A0096YM

      Remove the 3 bolts and insulator.

  29. REMOVE EXHAUST MANIFOLD


    1. A009BTK

      Remove the 2 nuts, 6 bolts and manifold.

    2. Remove the gasket.

  30. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A00JUOB

      Remove the 10 bolts, 2 nuts, oil filter bracket and gasket.

  31. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A009AG5

      Using a 24 mm deep socket wrench, remove the oil pressure switch.