ENGINE UNIT REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • The exhaust valve is filled with sodium. Sodium is a strong alkali which may produce a dangerous chemical reaction. Therefore, be very careful when handling and disposing of it.

  • Do not disassemble the exhaust valve for the following reasons: 1) If sodium enters your eyes, vision loss may occur. 2) If sodium contacts your skin, burns may occur. 3) If sodium is exposed to a flame and starts a fire due to the chemical reaction that takes place, burns may occur.

  • If the exhaust valve is damaged, remove the valve and perform the proper procedures to dispose of the sodium. (disposal preparation and actual disposal)

  • When removing a damaged exhaust valve, always wear rubber gloves and safety glasses.

  • Do not cut the exhaust valve to take out the sodium.

Tech Tips


  • The sodium inside the exhaust valve is safe as long as the sodium is not exposed to air.

  • Exhaust valves filled with sodium can be identified by confirming the "NA" identification mark.

  • Remove the exhaust valve.

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  • Dispose of exhaust valve.

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PROCEDURE


  1. REMOVE FAN AND GENERATOR V BELT

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  2. REMOVE GENERATOR ASSEMBLY

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  3. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

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  4. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B008IJY

      Remove the 2 bolts, 2 nuts and No. 1 compressor mounting bracket.

    2. Remove the 2 stud bolts from the cylinder block sub-assembly and stiffening crankcase assembly.

  5. REMOVE NO. 2 WATER BY-PASS PIPE

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  6. REMOVE PURGE VSV

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  7. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

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  8. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

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  9. DISCONNECT NO. 1 AND NO. 2 WATER BY-PASS HOSE


    1. B008HZ3

      Slide the clamp and disconnect the No. 1 water by-pass hose from the cylinder head sub-assembly.

    2. Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 1 water by-pass pipe.

  10. REMOVE NO. 2 PCV HOSE

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  11. REMOVE INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY


    1. B008GYZ

      Remove the 4 bolts, 2 nuts and intake manifold with intercooler assembly and throttle with motor body assembly.

    2. Remove the 2 No. 1 intake manifold to head gaskets from the intake manifold.

  12. REMOVE IGNITION COIL ASSEMBLY

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  13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  15. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  16. DISCONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

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  17. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  18. REMOVE ENGINE WIRE

  19. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B008GIY

      for Engine Upper Side:

      Remove the 2 bolts and 2 wire harness clamp brackets from the cylinder head cover sub-assembly.

    2. B008IXM

      for Engine Rear Side:

      Remove the 3 bolts and 3 wire harness clamp brackets from the cylinder head sub-assembly.

  20. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

  21. REMOVE OIL FILLER CAP GASKET


    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  22. REMOVE IDLER PULLEY SUB-ASSEMBLY

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  23. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  24. REMOVE NO. 8 ENGINE WIRE

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