ENGINE UNIT REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE COMPRESSOR STAY


    1. A006UJD

      Remove the compressor stay from the cylinder block.

  2. REMOVE GENERATOR ASSEMBLY


    1. A006UBF

      Remove the 3 bolts and generator.

  3. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A006TCS

      Remove the bolt, plate and No. 2 idler pulley.

  4. REMOVE IDLER PULLEY COVER PLATE


    1. A006V4H

      Using a screwdriver, remove the idler pulley cover plate.

  5. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A006TGT

      Remove the bolt and No. 1 idler pulley.

  6. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A006V64

      Remove the bolt, No. 4 water by-pass pipe and O-ring.

  7. REMOVE ENGINE MOUNTING BRACKET


    1. A006UPJ

      Remove the 4 bolts, 2 nuts and engine mounting bracket.

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A006WSD

      Remove the 3 bolts and V-ribbed belt tensioner.

      Note

      As the bolt heads are not as thick as typical bolts, be careful not to damage them during removal.

  9. REMOVE VACUUM PUMP ASSEMBLY


    1. A00EAYO

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump.

    3. Remove the 2 O-rings from the vacuum pump.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A00EB5RE01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Disconnect the No. 6 and No. 7 water by-pass hoses.

    2. A00E8R7

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

  11. REMOVE NO. 7 WATER BY-PASS HOSE

    A003C0A

  12. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A003C1D

  13. REMOVE EGR VALVE BRACKET


    1. A00EAGF

      Remove the 3 bolts and 2 EGR valve brackets.

  14. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A003BVE

      Disconnect the electric EGR control valve connector.

    2. A003CDBE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts and No. 2 EGR pipe.

    3. Remove the 2 gaskets.

  15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003AHE

      Remove the electric EGR control valve and gasket.

  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00E7VT

      Remove the 2 bolts and engine oil level dipstick guide.

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

  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  18. REMOVE INJECTION PIPE

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  19. REMOVE NO. 4 FUEL HOSE

    A00E7JG

  20. REMOVE COMMON RAIL ASSEMBLY


    1. A00E871

      Remove the 2 bolts and common rail.

  21. REMOVE INTAKE MANIFOLD INSULATOR


    1. A003CC9

      Remove the intake manifold insulator from the intake manifold.

  22. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A00EAXX

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  23. REMOVE NO. 1 GAS FILTER


    1. A003BBJ

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  24. REMOVE GAS FILTER BRACKET


    1. A003AWW

      Remove the 2 bolts and gas filter bracket.

  25. REMOVE ENGINE COVER BRACKET


    1. A003EJ9

      Remove the bolt and engine cover bracket.

  26. REMOVE NO. 2 INTAKE MANIFOLD


    1. A003DE3

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  27. REMOVE INTAKE MANIFOLD


    1. A003DELE01
      Text in Illustration
      *1 Nut

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

  28. REMOVE GLOW PLUG ASSEMBLY


    1. A006TCA

      Remove the 4 grommets.

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

    3. Using a 10 mm deep socket wrench, remove the 4 glow plugs.

  29. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A00E6YU

      Remove the No. 1 cylinder block insulator from the cylinder block.

  30. REMOVE WATER BY-PASS HOSE

    A003CG4

  31. REMOVE NO. 6 WATER BY-PASS HOSE

    A00EB4I

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    A00E8GW

  33. REMOVE NO. 4 WATER BY-PASS HOSE

    A00E7QM

  34. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A00EBC9

      Remove the 2 bolts and No. 2 water by-pass pipe from the water inlet housing.

  35. REMOVE FUEL HOSE PROTECTOR


    1. A003BGR

      Remove the bolt and fuel hose protector.

  36. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A003CV6

      Disconnect the exhaust fuel addition injector connector.

    2. A003BVV

      Turn the retainer as shown in the illustration.

    3. A003BLP

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A003D04E01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    5. Remove the union bolt, gasket and fuel tube.

  37. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY


    1. A003E5DE01
      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp

      Remove the bolt, washer, nozzle holder clamp, exhaust fuel addition injector and gasket.

  38. REMOVE FUEL INJECTOR SEAL


    1. A003ELAE01
      Text in Illustration
      *1 Fuel Injector Seal

      Remove the fuel injector seal from the exhaust fuel addition injector.

  39. REMOVE NO. 3 FUEL HOSE


    1. A003DB7

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the No. 3 fuel hose.

  40. REMOVE SUPPLY PUMP ASSEMBLY


    1. A006V9M

      Remove the 2 bolts, supply pump and No. 1 supply pump drive coupling.

    2. Remove the O-ring from the supply pump.

  41. REMOVE FUEL HOSE PROTECTOR


    1. A006WTQ

      Remove the fuel hose protector.

  42. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A006SGI

      Remove the 2 bolts, O-ring and No. 3 water by-pass pipe.

  43. REMOVE NO. 1 TURBO OIL PIPE


    1. A006VG8

      Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.

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


    1. A00EAA9

      Disconnect the 2 vacuum hoses.

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

  45. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A00EA6B

      Disconnect the 2 vacuum hoses.

    2. Remove the 5 bolts and vacuum switching valve bracket.

  46. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR


    1. A003CP1

      Remove the 5 bolts and No. 1 manifold converter insulator.

  47. REMOVE MANIFOLD STAY


    1. A003D1P

      Remove the bolt, nut and manifold stay.

  48. REMOVE NO. 2 MANIFOLD STAY


    1. A003AZX

      Remove the 3 bolts and No. 2 manifold stay.

  49. REMOVE NO. 2 EXHAUST MANIFOLD STAY


    1. A003DF4

      Remove the 2 bolts, nut and No. 2 exhaust manifold stay.

  50. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A003DW1

      Disconnect the 2 connectors.

    2. A003AVD

      Remove the 3 nuts and exhaust manifold converter.

    3. Remove the gasket from the turbocharger.

  51. REMOVE NO. 1 TURBO WATER HOSE (for Manual Transaxle)

    A006V3D

  52. REMOVE NO. 5 WATER BY-PASS HOSE (for Manual Transaxle)

    A006WB1

  53. REMOVE NO. 2 WATER BY-PASS HOSE (for Automatic Transaxle)

    A006TXG

  54. REMOVE EGR COOLER WITH PIPE ASSEMBLY


    1. A006SF6

      Disconnect the vacuum hose.

    2. A006VEDE01
      Text in Illustration
      *1 Nut

      Remove the 6 bolts, 2 nuts and EGR cooler with pipe.

    3. Remove the gasket from the No. 1 EGR pipe and the gasket from the EGR cooler.

    4. A006WQ4E01

      Remove the O-ring from the EGR cooler.

  55. REMOVE TURBO OIL OUTLET PIPE


    1. A006TR3E01
      Text in Illustration
      *1 Nut

      Remove the 2 nuts, 2 bolts, turbo oil outlet pipe and 2 gaskets.

  56. REMOVE NO. 1 TURBO INSULATOR


    1. A006U13

      Remove the 2 bolts and No. 1 turbo insulator.

  57. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A006WBA

      Remove the union bolt, gasket and No. 1 turbo water pipe.

  58. DISCONNECT NO. 3 WATER BY-PASS HOSE

    A006SRM

  59. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A006SNWE01
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt and gasket.

    2. Remove the bolt and No. 2 turbo water pipe.

  60. REMOVE NO. 5 WATER BY-PASS PIPE (for Automatic Transaxle)


    1. A006T8K

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

  61. REMOVE NO. 2 TURBO OIL PIPE


    1. A006WNME01

      Disconnect the vacuum hose.

    2. Remove the 2 union bolts, 2 gaskets and No. 2 turbo oil pipe.

  62. REMOVE TURBOCHARGER STAY


    1. A006VIIE01
      Text in Illustration
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

      Note

      Do not reuse the turbocharger stay.

  63. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A006WMSE02

    1. Disconnect the vacuum hose.

    2. Remove the 3 nuts, turbocharger and gasket.

  64. REMOVE EXHAUST MANIFOLD


    1. A006X71

      Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

  65. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A006X76

      Remove the 3 bolts and bearing bracket.