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. A010N6S

      Remove the compressor stay from the cylinder block.

  2. REMOVE GENERATOR ASSEMBLY


    1. A010ON5

      Remove the 3 bolts and generator.

  3. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A010RO2

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

  4. REMOVE IDLER PULLEY COVER PLATE


    1. A010O87

      Using a screwdriver, remove the idler pulley cover plate.

  5. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A010Q3N

      Remove the bolt and No. 1 idler pulley.

  6. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A010SH6

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

  7. REMOVE ENGINE MOUNTING BRACKET


    1. A010RJE

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

  8. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A010NFZ

      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. A00OR02

      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. A00OQTYE01
      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. A00OSP8

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

  11. REMOVE NO. 7 WATER BY-PASS HOSE

    A00OSGC

  12. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A00OVYQ

  13. REMOVE EGR VALVE BRACKET


    1. A00ORPA

      Remove the 3 bolts and 2 EGR valve brackets.

  14. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A00OQKV

      Disconnect the electric EGR control valve connector.

    2. A00OSQME01
      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. A00OW3B

      Remove the electric EGR control valve and gasket.

  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00OQW3

      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. A00OT1T

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

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

  18. REMOVE INJECTION PIPE SUB-ASSEMBLY

    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. A00OQOI

      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

    A00OSE6

  20. REMOVE COMMON RAIL ASSEMBLY


    1. A00OUME

      Remove the 2 bolts and common rail.

  21. REMOVE INTAKE MANIFOLD INSULATOR


    1. A00OSN4

      Remove the intake manifold insulator from the intake manifold.

  22. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A00OU6H

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  23. REMOVE NO. 1 GAS FILTER


    1. A00OUQK

      Disconnect the vacuum hose.

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

  24. REMOVE GAS FILTER BRACKET


    1. A00OVKD

      Remove the 2 bolts and gas filter bracket.

  25. REMOVE ENGINE COVER BRACKET


    1. A00OURK

      Remove the bolt and engine cover bracket.

  26. REMOVE NO. 2 INTAKE MANIFOLD


    1. A00OUSS

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

  27. REMOVE INTAKE MANIFOLD


    1. A00OVS2E01
      Text in Illustration
      *1 Nut

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

  28. REMOVE GLOW PLUG ASSEMBLY


    1. A010RJ6

      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. A00ORUX

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

  30. REMOVE WATER BY-PASS HOSE

    A00ORYW

  31. REMOVE NO. 6 WATER BY-PASS HOSE

    A00OUJ2

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    A00OR5P

  33. REMOVE NO. 4 WATER BY-PASS HOSE

    A00ORW3

  34. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A00OQO4

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

    2. Remove the O-ring from the No. 2 water by-pass pipe.

  35. REMOVE FUEL HOSE PROTECTOR


    1. A00OUIW

      Remove the bolt and fuel hose protector.

  36. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A00OU7J

      Disconnect the exhaust fuel addition injector connector.

    2. A00OU58

      Turn the retainer as shown in the illustration.

    3. A00ORLS

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A00OTGY

      Remove the check valve and gasket.

      Text in Illustration
      A00OVAR Check Valve

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

  37. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY


    1. A00OTPLE01
      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. A00OW1FE01
      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. A00OTCD

      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. A010NN8

      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. A010SQ1

      Remove the fuel hose protector from the cylinder head.

  42. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A010N9E

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

  43. REMOVE NO. 1 TURBO OIL PIPE


    1. A010SFZ

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

  44. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. Disconnect the vacuum regulating valve connector.

    2. A00OQVH

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  45. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A00OV8YE01
      Text in Illustration
      *a Pinch

      Pinch the clip as shown in the illustration and pull out the VSV connector.

    2. A00OR7I

      Disconnect the 2 vacuum hoses.

    3. Using a 4 mm hexagon socket wrench, remove the 2 bolts and VSV.

  46. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A00OUD1

      Detach the 10 clamps and remove the 2 vacuum transmitting hoses.

  47. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR


    1. A00OSDD

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

  48. REMOVE MANIFOLD STAY


    1. A00OUQN

      Remove the bolt, nut and manifold stay.

  49. REMOVE NO. 2 MANIFOLD STAY


    1. A00OUX2

      Remove the 3 bolts and No. 2 manifold stay.

  50. REMOVE NO. 2 EXHAUST MANIFOLD STAY


    1. A00OR9S

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

  51. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A00OV5A

      Disconnect the 2 connectors.

    2. A00OQH9

      Remove the 3 nuts and exhaust manifold converter.

    3. Remove the gasket from the turbocharger.

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

    A00ORM0

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

    A00OV0A

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

    A00OSV5

  55. REMOVE EGR COOLER WITH PIPE ASSEMBLY


    1. A00OVQZ

      Disconnect the vacuum hose.

    2. A00OUWBE01
      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. A00OSTJE01

      Remove the O-ring from the EGR cooler.

  56. REMOVE TURBO OIL OUTLET PIPE


    1. A00OV8DE01
      Text in Illustration
      *1 Nut

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

  57. REMOVE NO. 1 TURBO INSULATOR


    1. A00OUYW

      Remove the 2 bolts and No. 1 turbo insulator.

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


    1. A00OQF9

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

  59. DISCONNECT NO. 3 WATER BY-PASS HOSE

    A00OTZV

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


    1. A00OQQTE01
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt and gasket.

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

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


    1. A00ORIM

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

  62. REMOVE NO. 2 TURBO OIL PIPE


    1. A00OTKXE01

      Disconnect the vacuum hose.

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

  63. REMOVE TURBOCHARGER STAY


    1. A00OVI1E01
      Text in Illustration
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

      Note

      Do not reuse the turbocharger stay.

  64. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A00OT27E02

    1. Disconnect the vacuum hose.

    2. Remove the 3 nuts, turbocharger and gasket.

    3. A00OVBJ

      Using an E8 "TORX" wrench, remove the stud bolt.

  65. REMOVE EXHAUST MANIFOLD


    1. A010N5Q

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

  66. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A010N7C

      Remove the 3 bolts and bearing bracket.