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 FAN AND GENERATOR V BELT


    1. Using SST and a 22 mm wrench, rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the belt.

      SST
      09216-42010

      CAUTION:


      • Be careful as the wrench only fits loosely on the belt tensioner tool set point. The wrench may come off the set point and cause injuries.

      • Be careful that your hands do not become jammed between parts such as the belt, pulleys, etc.

      Note

      Make sure SST is installed as shown in the illustration. If not, SST and/or the belt may not be able to be removed.

      A01ISZME01

  2. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01IURV

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. Remove the 2 stud bolts and compressor with pulley assembly.

  3. REMOVE COMPRESSOR STAY


    1. A01IPS1

      Remove the compressor stay from the cylinder block sub-assembly.

  4. REMOVE GENERATOR ASSEMBLY


    1. A01ISLO

      Remove the 3 bolts and generator assembly.

  5. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01ITQD

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly.

  6. REMOVE IDLER PULLEY COVER PLATE


    1. A01IRN6

      Using a screwdriver, remove the idler pulley cover plate.

  7. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01IU16E01
      Text in Illustration
      *1 Tape

      Using a screwdriver, remove the idler pulley cover plate.

      Tech Tips

      Tape the screwdriver tip before use.

  8. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A01IR3I

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

  9. REMOVE ENGINE MOUNTING BRACKET


    1. Remove the stud bolt from the engine mounting bracket.

    2. A01IUBZ

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

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01IS50

      Remove the 3 bolts and V-ribbed belt tensioner assembly.

      Note

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

  11. REMOVE VACUUM PUMP ASSEMBLY


    1. A01IOLN

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump assembly.

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

  12. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01IU98E01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Slide the 2 clamps and disconnect the No. 6 water by-pass hose and No. 7 water by-pass hose from the diesel throttle body assembly.

    2. A01IS0N

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

  13. REMOVE NO. 7 WATER BY-PASS HOSE


    1. A01IUFE

      Slide the clamp and remove the No. 7 water by-pass hose from the electric EGR control valve assembly.

  14. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A01INDM

    1. Slide the clamp and disconnect the No. 8 water by-pass hose from the electric EGR control valve assembly.

  15. REMOVE EGR VALVE BRACKET


    1. A01IPI2

      Remove the 3 bolts and 2 EGR valve brackets.

  16. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts, No. 2 EGR pipe sub-assembly and 2 gaskets.

  17. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve assembly and gasket.

  18. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IN7K

      Remove the 2 bolts and engine oil level dipstick guide.

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

  19. 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. A01ITN1

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

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

  20. 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. A01IO2G

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

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

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

    4. Remove the 4 injection pipes.

  21. REMOVE NO. 4 FUEL HOSE


    1. A01IORV

      Slide the 2 clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe and common rail assembly.

  22. REMOVE COMMON RAIL ASSEMBLY


    1. A01ITVG

      Remove the 2 bolts and common rail assembly.

  23. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IO3Y

      Remove the intake manifold insulator from the intake manifold.

  24. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and diesel turbo pressure sensor.

  25. REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

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

  26. REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  27. REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  28. REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

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

  29. REMOVE INTAKE MANIFOLD


    1. A01IOHHE01
      Text in Illustration
      *1 Nut

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

    2. Remove the gasket from the cylinder head.

  30. REMOVE GLOW PLUG ASSEMBLY


    1. Remove the 4 glow plug screw grommets.

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

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

  31. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A01INKR

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

  32. REMOVE WATER BY-PASS HOSE


    1. A01IQEK

      Slide the 2 clamps and remove the water by-pass hose from the water outlet and oil cooler assembly.

  33. REMOVE NO. 6 WATER BY-PASS HOSE


    1. A01INLK

      Slide the clamp and remove the No. 6 water by-pass hose from the water outlet.

  34. REMOVE NO. 8 WATER BY-PASS HOSE


    1. A01IO0M

      Slide the clamp and remove the No. 8 water by-pass hose from the No. 3 water by-pass pipe.

  35. REMOVE NO. 4 WATER BY-PASS HOSE


    1. A01ITEU

      Slide the 2 clamps and remove the No. 4 water by-pass hose from the water inlet housing and cylinder head sub-assembly.

  36. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01IP5C

      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.

  37. REMOVE NO. 2 FUEL PIPE (for CCo)


    1. A01IN5Z

      Remove the check valve and gasket.

      Text in Illustration
      A01ISER Check Valve

    2. Remove the union bolt, gasket and No. 2 fuel pipe.

  38. REMOVE FUEL HOSE PROTECTOR (for DPF)


    1. A01INWG

      Remove the bolt and fuel hose protector.

  39. REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. A01IT57

      Disconnect the exhaust fuel addition injector connector.

    2. A01IQ6B

      Turn the retainer as shown in the illustration.

    3. A01IUL8

      Disconnect the fuel tube sub-assembly from the exhaust fuel addition injector assembly.

    4. A01INMW

      Remove the check valve and gasket.

      Text in Illustration
      A01ISER Check Valve

    5. Remove the union bolt, gasket and fuel tube sub-assembly.

  40. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)


    1. A01IQULE01
      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp

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

  41. REMOVE FUEL INJECTOR SEAL (for DPF)


    1. A01IR8Q

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

  42. REMOVE NO. 3 FUEL HOSE


    1. A01IP50

      Slide the 2 clamps and remove the No. 3 fuel hose from the supply pump assembly and No. 2 nozzle leakage pipe.

  43. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01IQWG

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

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

  44. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01ISIN

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

  45. REMOVE NO. 1 TURBO OIL PIPE


    1. A01IN86

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

  46. REMOVE VACUUM REGULATING VALVE ASSEMBLY (for CCo)


    1. Disconnect the vacuum regulating valve connector.

    2. A01IQN9

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  47. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01ITBIE01
      Text in Illustration
      *a Pinch

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

    2. A01IQO4

      Disconnect the 2 vacuum hoses.

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

  48. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IO8X

      for CCo:

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

    2. A01IP7L

      for DPF:

      Detach the 8 clamps and remove the 2 vacuum transmitting hoses.

  49. REMOVE WIRE HARNESS CLAMP BRACKET (for DPF)


    1. A01ISVH

      Remove the bolt and No. 1 wiring harness clamp bracket.

  50. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR (for CCo)


    1. A01IU23

      Remove the 4 bolts and No. 1 manifold converter insulator.

  51. REMOVE NO. 4 MANIFOLD CONVERTER INSULATOR (for DPF)


    1. A01ITKK

      Remove the 4 bolts and No. 4 manifold converter insulator.

  52. REMOVE MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY (for DPF)


    1. A01IQF5

      Remove the bolt and manifold converter insulator sub-assembly.

  53. REMOVE MANIFOLD STAY (for CCo)


    1. A01IQXB

      Remove the bolt, nut and manifold stay.

  54. REMOVE MANIFOLD STAY (for DPF)


    1. A01IUEH

      Remove the bolt, nut and manifold stay.

  55. REMOVE NO. 2 MANIFOLD STAY (for CCo)


    1. A01ISVT

      Remove the 3 bolts and No. 2 manifold stay.

  56. REMOVE NO. 2 MANIFOLD STAY (for DPF)


    1. A01IQ6M

      Remove the 3 bolts and No. 2 manifold stay.

  57. REMOVE NO. 2 EXHAUST MANIFOLD STAY (for CCo)


    1. A01IU58

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

  58. REMOVE NO. 2 EXHAUST MANIFOLD STAY (for DPF)


    1. A01IUQ6

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

  59. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for CCo)


    1. A01IQ9Q

      Remove the 3 nuts, exhaust manifold converter and gasket.

  60. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for DPF)


    1. Disconnect the 2 connectors.

    2. A01ITX8

      Remove the 3 nuts, exhaust manifold converter sub-assembly and gasket.

  61. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A01IR2ME01
      Text in Illustration
      *A for CCo
      *B for DPF

      for CCo:

      Slide the 2 clamps and remove the No. 2 water by-pass hose from the EGR cooler and No. 5 water by-pass hose.

    2. for DPF:

      Slide the 2 clamps and remove the No. 2 water by-pass hose from the EGR cooler and turbo oil outlet pipe.

  62. REMOVE EGR COOLER WITH PIPE ASSEMBLY


    1. A01IO7O

      Disconnect the vacuum hose.

    2. A01IO7IE01
      Text in Illustration
      *1 Nut

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

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

    4. A01IUDKE01
      Text in Illustration
      *1 O-Ring

      Remove the O-ring from the EGR cooler.

  63. REMOVE TURBOCHARGER SUB-ASSEMBLY


  64. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01IP75

      Remove the 3 bolts and drive shaft bearing bracket.