ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

Note:

  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.

PROCEDURE

  1. DISCONNECT ENGINE WIRE

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  2. REMOVE FAN AND GENERATOR V BELT

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  3. REMOVE COOLER COMPRESSOR ASSEMBLY WITH PULLEY

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  4. REMOVE COMPRESSOR STAY

    1. A203729

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

  5. REMOVE GENERATOR ASSEMBLY

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  6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  7. REMOVE IDLER PULLEY COVER PLATE

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  8. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

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  9. REMOVE NO. 4 WATER BY-PASS PIPE

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  10. REMOVE ENGINE MOUNTING BRACKET

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  11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  12. REMOVE VACUUM PUMP ASSEMBLY

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  13. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  14. REMOVE NO. 7 WATER BY-PASS HOSE

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  15. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  16. REMOVE EGR VALVE BRACKET

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  17. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  19. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  20. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  21. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  22. REMOVE NO. 4 FUEL HOSE

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  23. REMOVE COMMON RAIL ASSEMBLY

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  24. REMOVE INTAKE MANIFOLD INSULATOR

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  25. REMOVE DIESEL TURBO PRESSURE SENSOR

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  26. REMOVE NO. 1 GAS FILTER

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  27. REMOVE GAS FILTER BRACKET

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  28. REMOVE ENGINE COVER BRACKET

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  29. REMOVE NO. 2 INTAKE MANIFOLD

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  30. REMOVE INTAKE MANIFOLD

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  31. REMOVE GLOW PLUG ASSEMBLY

    1. A263725

      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 assemblies.

  32. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

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  33. REMOVE WATER BY-PASS HOSE

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  34. REMOVE NO. 6 WATER BY-PASS HOSE

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  35. REMOVE NO. 8 WATER BY-PASS HOSE

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  36. REMOVE NO. 4 WATER BY-PASS HOSE

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  37. REMOVE NO. 2 WATER BY-PASS PIPE

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  38. REMOVE FUEL HOSE PROTECTOR

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  39. REMOVE FUEL TUBE SUB-ASSEMBLY

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  40. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

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  41. REMOVE FUEL INJECTOR SEAL

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  42. REMOVE NO. 3 FUEL HOSE

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  43. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    1. A203055

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

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

  44. REMOVE NO. 3 WATER BY-PASS PIPE

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  45. REMOVE NO. 1 TURBO OIL PIPE

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  46. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  47. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

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  48. REMOVE NO. 1 WIRING HARNESS CLAMP BRACKET

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  49. REMOVE NO. 4 MANIFOLD CONVERTER INSULATOR

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  50. REMOVE MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY

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  51. REMOVE MANIFOLD STAY

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  52. REMOVE NO. 2 MANIFOLD STAY

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  53. REMOVE NO. 2 EXHAUST MANIFOLD STAY

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  54. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  55. REMOVE NO. 2 WATER BY-PASS HOSE

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  56. REMOVE EGR COOLER WITH PIPE ASSEMBLY

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  57. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  58. REMOVE EXHAUST MANIFOLD

    1. A111244

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

  59. REMOVE DRIVE SHAFT BEARING BRACKET

    1. A129570

      Remove the 3 bolts and drive shaft bearing bracket.