БЛОК ДВИГАТЕЛЯ СНЯТИЕ


  1. REMOVE NO. 1 TURBO INSULATOR

    A01186N

    1. Remove the 2 bolts and the No. 1 turbo insulator.

  2. REMOVE TURBOCHARGER STAY

    A0117OT

    Remove the 2 bolts, nut and the turbocharger stay.

  3. REMOVE NO. 2 TURBOCHARGER STAY

    A0119B0

    1. Remove the bolt, nut and the No. 2 turbocharger stay.

  4. REMOVE MANIFOLD STAY

    A011AXJ

    1. Remove the 2 bolts and manifold stay.

  5. REMOVE TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD

    A0118RA

    1. Remove the 11 nuts and the turbocharger with the exhaust manifold.

    2. Remove the 2 gaskets from the cylinder head and cylinder block.

    3. A0119LI

      Remove the 2 nuts and the turbo oil inlet pipe from the turbocharger.

    4. Remove the gasket from the turbocharger.

  6. REMOVE GENERATOR ASSEMBLY

    A011BVO

    1. Remove the 2 bolts, nut and generator.

  7. REMOVE GENERATOR BRACKET

    A011866

    1. Remove the bolt and the generator bracket.

  8. REMOVE EGR WITH COOLER PIPE ASSEMBLY

    A01190W

    1. Disconnect the vacuum transmitting hose.

    2. Disconnect the No. 1 vacuum transmitting hose.

    3. A0119Y8

      Disconnect the 2 vacuum hoses and No. 1 oil hose.

    4. Disconnect the No. 2 oil cooler hose.

    5. Disconnect the No. 2 water by-pass hose.

    6. A0119M3

      Remove the 4 bolts, 2 nuts and the EGR with cooler pipe assembly.

    7. Remove the 2 gaskets from the cylinder head and the electric EGR control valve.

  9. REMOVE NO. 5 ENGINE COVER


    1. A01176L

      Disengage the 2 claws.

    2. Lift the No. 5 engine cover to disengage the hook and remove it from the No. 1 EGR cooler bracket.

  10. REMOVE NO. 1 EGR COOLER BRACKET

    A01197G

    1. Disconnect the vacuum hose.

    2. Remove the 2 bolts and the No. 1 EGR cooler bracket.

  11. REMOVE HARNESS BRACKET

    A011AOS

    1. Disconnect the vacuum hose from the vacuum pump.

    2. Remove the bolt and harness bracket.

  12. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A0117TJ

    1. Disconnect the No. 4 water by-pass hose.

    2. Disconnect the No. 3 water by-pass hose.

    3. Remove the 2 bolts and the electric EGR control valve.

    4. Remove the gasket from the intake air connector.

  13. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

    A0119J6

    1. Remove the 2 bolts, 2 nuts and the intake air connector with the diesel throttle body.

    2. Remove the gasket from the cylinder head.

  14. REMOVE NO. 2 INJECTION PIPE CLAMP


    1. A0118OJ

      Remove the nut and both sides of the No. 2 injection pipe clamp.

  15. REMOVE NO. 1 INJECTION PIPE CLAMP


    1. A0119HS

      Remove the 2 nuts and both sides of the No. 1 injection pipe clamp.

  16. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. A0117KJE01
      Text in Illustration
      *1 No. 1 Injection Pipe
      *2 No. 2 Injection Pipe
      *3 No. 3 Injection Pipe

      Using a union nut wrench (17 mm), separate the union nut from the injector first.

    2. Then remove the union nut from the common rail, and remove the injection pipe.

    3. After removing the injection pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.

  17. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  18. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  19. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. Remove the 4 screw grommets.

    2. A011B7B

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

  20. REMOVE GLOW PLUG ASSEMBLY

    A0118CE

    1. Remove the 4 glow plugs.

  21. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A011AZT

      Remove the No. 2 intake manifold insulator.

  22. REMOVE NOZZLE LEAKAGE PIPE SET CLAMP

    A011927

    1. Remove the 3 nozzle leakage pipe set clamps.

  23. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    A0118JV

    1. Remove the retainer spring disconnect the nozzle leakage pipe.

    2. A01171XE01
      Text in Illustration
      *1 Lock Bush

      Pull up the lock bush as shown in the illustration and remove the nozzle leakage pipe.

      Note

      Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.

  24. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01195RE01
      Text in Illustration
      *1 Washer
      *2 Nozzle holder clamp
      *3 Nozzle holder clamp seat

      Remove the 4 bolts, 4 washers, and 4 nozzle holder clamps.

  25. REMOVE NOZZLE HOLDER CLAMP SEAT


    1. A0117L1

      Remove the 4 nozzle holder clamp seats from the cylinder head.

  26. REMOVE INJECTOR ASSEMBLY


    1. A011BHC

      Remove the 4 injectors from the cylinder head.

      Tech Tips


      • Each injector assembly has its own fuel injection part number. When replacing the injectors, store them in the correct order so that they can be returned to their original locations when reassembled.

      • Arrange the injectors, clamps, washers, bolts and clamp seats in the correct order.

  27. REMOVE INJECTION NOZZLE SEAT


    1. A011BC0

      Remove the 4 injection nozzle seats from the injector or cylinder head.

      Tech Tips

      When removing the injector, check that the injector nozzle seat is either attached to the injector, or remains in the cylinder head.

  28. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A0117G5

      Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), separate the union nut from the supply pump first.

    2. Then remove the union nut from the common rail, and remove the fuel inlet pipe.

    3. After removing the fuel inlet pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.

  29. REMOVE NO. 2 FUEL HOSE

    A0118ZU

    1. Remove the No. 2 fuel hose.

  30. REMOVE SUPPLY PUMP ASSEMBLY

    A0119GH

    1. Remove the 3 bolts and supply pump.

    2. A0118J9

      Remove the O-ring.

  31. REMOVE SUPPLY PUMP DRIVE COUPLING


    1. A0119VH

      Remove the supply pump driving coupling.

      Note

      When removing the supply pump, make sure that the drive coupling does not fall off, as it can be easily removed. If the drive coupling falls off, replace it with a new one.

  32. REMOVE COMMON RAIL ASSEMBLY

    A0119IB

    1. Remove the 2 bolts and common rail.

      Note

      Do not remove the fuel pressure sensor or fuel pressure regulator.

  33. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A01194J

    1. Remove the No. 1 intake manifold insulator.

  34. REMOVE NO. 2 CYLINDER HEAD COVER

    A0118GJ

    1. Remove the 2 bolts and the 2 harness brackets.

    2. A011756

      Remove the No. 2 cylinder head cover.

  35. REMOVE NO. 2 OIL COOLER HOSE


    1. A01192S

      Remove the hose clamp.

    2. A0118UH

      Disconnect the 2 clamps and remove the No. 2 oil cooler hose.

  36. REMOVE OIL COOLER HOSE SUB-ASSEMBLY

    A011A65

    1. Remove the oil cooler hose.

  37. REMOVE NO. 4 WATER BY-PASS HOSE

    A0119KJ

    1. Remove the No. 4 water by-pass hose.

  38. REMOVE NO. 3 WATER BY-PASS HOSE

    A011A5W

    1. Remove the No. 3 water by-pass hose.

  39. REMOVE NO. 2 WATER BY-PASS HOSE

    A0119F0

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

  40. REMOVE WATER BY-PASS HOSE

    A0117LN

    1. Remove the water by-pass hose.

  41. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    A011BJH

    1. Remove the 2 bolts and the water by-pass pipe.

    2. Remove the O-ring from the water by-pass pipe.

  42. REMOVE WATER INLET HOSE RH

    A0118Z3

    1. Remove the water inlet hose RH.

  43. REMOVE WATER INLET HOSE LH

    A0116WZ

    1. Remove the water inlet hose LH.

  44. REMOVE WATER INLET PIPE

    A011BY9

    1. Remove the 2 bolts and the water inlet pipe.

  45. REMOVE ENGINE OIL LEVEL DIPSTICK

  46. REMOVE OIL LEVEL DIPSTICK GUIDE

    A0119KF

    1. Remove the 2 bolts and the oil level dipstick guide.

    2. Remove the O-ring from the oil level dipstick guide.

  47. REMOVE CAMSHAFT POSITION SENSOR

    A0118LM

    1. Remove the bolt and harness bracket.

    2. Remove the bolt and camshaft position sensor.

  48. REMOVE VACUUM PUMP ASSEMBLY

    A0118TC

    1. Remove the 2 bolts and vacuum pump.

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

  49. REMOVE IDLER PULLEY SUB-ASSEMBLY

    A01192A

    1. Remove the bolt and idler pulley.

  50. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A0117ML

    1. Remove the 2 bolts and the V-ribbed belt tensioner.

  51. REMOVE HARNESS BRACKET (w/o Air Conditioning System)

    A011AE6

    1. Remove the bolt and harness bracket.

  52. REMOVE CYLINDER BLOCK SIDE COVER

    A0119TW

    1. Remove the bolt, washer plate and the cylinder block side cover.

  53. REMOVE NO. 2 OIL PAN COVER SILENCER

    A01176G

    1. Remove the 2 bolts, 2 washer plates and the No. 2 oil pan cover silencer.

  54. REMOVE OIL PAN COVER

    A0119HI

    1. Remove the bolt, washer plate and the oil pan cover.