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 V-ribbed belt tensioner pulley counterclockwise to loosen the fan and generator V belt tension. Then remove the fan and generator V 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 fan and generator V belt, pulleys, etc.

      Note

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

      A01ISZME02
      Text in Illustration
      *A w/o Air Conditioning System *B w/ Air Conditioning System

  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. A01IU16E01
      Text in Illustration
      *1 Tape

      Using a screwdriver, remove the idler pulley cover plate.

      Tech Tips

      Tape the screwdriver tip before use.

  7. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01IR41

      Remove the bolt and No. 1 idler pulley sub-assembly.

  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.

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

  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

      Disconnect the No. 6 and No. 7 water by-pass hoses.

    2. A01IS0N

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

  13. REMOVE NO. 7 WATER BY-PASS HOSE

    A01IUFE

  14. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A01INDM

      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 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 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. 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

    A01IORV

  22. REMOVE COMMON RAIL ASSEMBLY


    1. A01ITVG

      Remove the 2 bolts and common rail.

  23. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IQK4

      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 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.

  30. REMOVE GLOW PLUG ASSEMBLY


    1. A01IPD1

      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 sub-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

    A01INLK

  34. REMOVE NO. 8 WATER BY-PASS HOSE

    A01IO0M

  35. REMOVE NO. 4 WATER BY-PASS HOSE

    A01ITEU

  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 FUEL HOSE PROTECTOR


    1. A01INWG

      Remove the bolt and fuel hose protector.

  38. REMOVE FUEL TUBE SUB-ASSEMBLY


    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.

  39. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY


    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.

  40. REMOVE FUEL INJECTOR SEAL


    1. A01IR8Q

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

  41. REMOVE NO. 3 FUEL HOSE

    A01IP50

  42. 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.

  43. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01ISIN

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

  44. REMOVE NO. 1 TURBO OIL PIPE


    1. A01IN86

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

  45. 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.

  46. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    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 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IO8X

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

  48. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR


    1. A01IO22

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

  49. REMOVE MANIFOLD STAY


    1. A01IUEH

      Remove the bolt, nut and manifold stay.

  50. REMOVE NO. 2 MANIFOLD STAY


    1. A01IQ6M

      Remove the 3 bolts and No. 2 manifold stay.

  51. REMOVE NO. 2 EXHAUST MANIFOLD STAY


    1. A01IUQ6

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

  52. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01IRLJ

      Disconnect the 2 connectors.

    2. A01IQ9Q

      Remove the 3 nuts, exhaust manifold converter and gasket.

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

    A01IRIA

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

    A01IQE7

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

    A01IN2K

  56. 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.

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

    4. A01IPU2E01

      Remove the O-ring from the EGR cooler.

  57. REMOVE TURBO OIL OUTLET PIPE


    1. A01IUAWE01
      Text in Illustration
      *1 Nut

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

  58. REMOVE NO. 1 TURBO INSULATOR


    1. A01IORZ

      Remove the 2 bolts and No. 1 turbo insulator.

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


    1. A01IND1

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

  60. DISCONNECT NO. 3 WATER BY-PASS HOSE

    A01IRXI

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


    1. A01INILE01
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt and gasket.

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

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


    1. A01ITDU

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

  63. REMOVE NO. 2 TURBO OIL PIPE


    1. A01ITZZE01

      Disconnect the vacuum hose.

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

  64. REMOVE TURBOCHARGER STAY


    1. A01IOF8E01
      Text in Illustration
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

      Note

      Do not reuse the turbocharger stay.

  65. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A01IMY9E02

    1. Disconnect the vacuum hose.

    2. Remove the 3 nuts, turbocharger and gasket.

  66. REMOVE EXHAUST MANIFOLD


    1. A01IU0T

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

  67. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01IP75

      Remove the 3 bolts and drive shaft bearing bracket.