ENGINE UNIT REMOVAL

PROCEDURE

1. REMOVE ENGINE COVER BRACKET

   

   
   

   1. Remove the bolt and engine cover bracket.

2. REMOVE GENERATOR ASSEMBLY

   

   
   

   1. Remove the 2 bolts and generator.

3. REMOVE GENERATOR BRACKET

   

   
   

   1. Remove the 2 bolts and the generator bracket.

4. REMOVE EGR WITH COOLER PIPE ASSEMBLY

   

   
   

   1. Disconnect the 3 vacuum transmitting hoses.

   2. Disconnect the vacuum hose.

   3. Disconnect the No. 2 oil cooler hose.

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

   5. 

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

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

5. REMOVE NO. 1 EGR COOLER BRACKET

   
   

   1. 3-Bolt Type:

      
      

      1. Remove the 3 bolts and the No. 1 EGR cooler bracket.

   2. 2-Bolt Type:

      
      
      1. 

         Text in Illustration

         *A	3-Bolt Type
         *B	2-Bolt Type

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

6. REMOVE HARNESS BRACKET

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7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

   Click here

8. REMOVE ENGINE OIL LEVEL DIPSTICK

9. REMOVE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

   

   
   

   1. Remove the bolt and the oil level dipstick guide.

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

10. REMOVE NO. 1 OIL HOSE

    

    
    

    1. Disconnect the hose clamp and remove the No. 1 oil hose.

11. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

    

    
    

    1. Disconnect the hose clamp.

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

    3. Remove the gasket from the cylinder head.

12. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

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13. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

14. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

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15. REMOVE NO. 1 GLOW PLUG CONNECTOR

    
    

    1. Remove the 4 screw grommets.

    2. 

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

16. REMOVE GLOW PLUG ASSEMBLY

    

    
    

    1. Remove the 4 glow plugs.

17. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

18. REMOVE NOZZLE LEAKAGE PIPE SET CLAMP

    

    
    

    1. Remove the 3 nozzle leakage pipe set clamps.

19. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    

    
    

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

    2. 

       Text in Illustration

       *1

       Lock Bush

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

       Note

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

20. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

21. REMOVE NOZZLE HOLDER CLAMP SEAT

    Click here

22. REMOVE INJECTOR ASSEMBLY

    Click here

23. REMOVE INJECTION NOZZLE SEAT

    Click here

24. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

25. REMOVE NO. 2 FUEL HOSE

    

    
    

    1. Remove the No. 2 fuel hose.

26. REMOVE SUPPLY PUMP ASSEMBLY

    

    
    

    1. Disconnect the No. 1 fuel hose.

    2. 

       Remove the 3 bolts and supply pump.

    3. 

       Remove the O-ring.

27. REMOVE SUPPLY PUMP DRIVE COUPLING

    Click here

28. REMOVE COMMON RAIL ASSEMBLY

    

    
    

    1. Remove the 2 bolts and common rail.

       Note

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

29. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    

    
    

    1. Remove the No. 1 intake manifold insulator.

30. REMOVE NO. 2 CYLINDER HEAD COVER

    

    
    

    1. Remove the No. 2 cylinder head cover.

31. REMOVE OIL COOLER HOSE

    

    
    

    1. Remove the oil cooler hose.

32. REMOVE NO. 2 OIL COOLER HOSE

    

    
    

    1. Remove the 2 hose clamps.

    2. 

       Disconnect the 3 hose clamps and remove the No. 2 oil cooler hose.

33. REMOVE NO. 4 WATER BY-PASS HOSE

    

    
    

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

34. REMOVE NO. 3 WATER BY-PASS HOSE

    

    
    

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

35. REMOVE NO. 2 WATER BY-PASS HOSE

    

    
    

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

36. REMOVE WATER BY-PASS HOSE

    

    
    

    1. Remove the water by-pass hose.

37. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    

    
    

    1. Remove the 2 hose clamps.

    2. 

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

    3. Remove the O-ring from the No. 1 water by-pass pipe.

38. REMOVE INLET WATER HOSE RH

    

    
    

    1. Remove the inlet water hose RH.

39. REMOVE INLET WATER HOSE LH

    

    
    

    1. Remove the inlet water hose LH.

40. REMOVE INLET WATER PIPE

    

    
    

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

41. REMOVE VACUUM PUMP ASSEMBLY

    

    
    

    1. Remove the 2 bolts and vacuum pump.

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

42. REMOVE CAMSHAFT POSITION SENSOR

    

    
    

    1. Remove the bolt and camshaft position sensor.

43. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    

    
    

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

44. REMOVE HARNESS BRACKET

    

    
    

    1. Remove the 2 bolts and 2 harness brackets.

45. REMOVE NO. 5 ENGINE COVER

    

    
    

    1. Remove the 2 bolts, 2 washer plates and the No. 5 engine cover.

46. REMOVE NO. 2 OIL PAN COVER SILENCER

    

    
    

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

47. REMOVE OIL PAN COVER

    

    
    

    1. Remove the 2 bolts, 2 washer plates and the oil pan cover.