ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE WATER FILLER SUB-ASSEMBLY

    A005L7H

    1. Loosen the hose clamp and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

    2. Remove the 2 nuts and the water filler sub-assembly.

  2. DISCONNECT INLET HEATER WATER HOSE A


    1. A005JDJ

      Loosen the hose clamp and disconnect the inlet heater water hose A.

  3. DISCONNECT OUTLET WATER BY-PASS


    1. A005KEM

      Loosen the hose clamp and disconnect the outlet water by-pass.

  4. REMOVE GENERATOR ASSEMBLY

    Click here

  5. REMOVE GENERATOR BRACKET


    1. A005IZN

      Remove the nut and generator bracket.

  6. REMOVE EGR VALVE ASSEMBLY

    Click here

  7. REMOVE NO. 1 IGNITION COIL

    Click here

  8. REMOVE ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY


    1. A005KC6

      Remove the engine oil level dipstick sub-assembly.

  9. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    Click here

  10. REMOVE INTAKE MANIFOLD

    Click here

  11. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A005GDX

      Remove the bolt and the engine oil level dipstick guide.

  13. REMOVE EGR DELIVERY CHAMBER


    1. A005M1Z

      Remove the EGR delivery chamber and No. 1 intake manifold gasket.

  14. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  15. REMOVE NO. 1 OIL PIPE

    Click here

  16. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A005IPG

      Remove the nut and manifold absolute pressure sensor.

  17. REMOVE BOOSTER VACUUM TUBE


    1. A005JZD

      Remove the 2 bolts and the booster vacuum tube.

  18. REMOVE ENGINE WIRE


    1. Disconnect all sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness.

  19. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A005I84

      Remove the bolt and wire harness clamp bracket.

  20. REMOVE NO. 1 OUTLET WATER STAY


    1. A005KS7

      Remove the bolt and No. 1 outlet water stay.

  21. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  22. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  23. REMOVE MANIFOLD SUPPORT BRACKET

    Click here

  24. REMOVE EXHAUST MANIFOLD

    Click here

  25. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A005LUT

      Loosen the hose clamp and disconnect the No. 3 water by-pass hose.

  26. REMOVE NO. 1 WATER HOSE CLAMP BRACKET


    1. A005J5E

      Remove the bolt and No. 1 water hose clamp bracket.

  27. REMOVE DRIVE SHAFT HEAT INSULATOR BRACKET


    1. A005HN9

      Remove the bolt, nut, and drive shaft heat insulator bracket.

  28. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A005IMS

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