ENGINE UNIT(w/o Glow Plug Controller) REMOVAL

PROCEDURE

  1. REMOVE ENGINE COVER BRACKET (w/ No. 1 Engine Cover)

    1. A200036

      Remove the bolt and engine cover bracket from the engine mounting bracket RH.

  2. REMOVE GENERATOR ASSEMBLY

    1. A200037

      Remove the 2 bolts and generator assembly.

  3. REMOVE GENERATOR BRACKET

    1. A200102

      Remove the 2 bolts and generator bracket from the cylinder block sub-assembly.

  4. REMOVE EGR WITH COOLER PIPE ASSEMBLY

    1. A236363

      Disconnect the 3 vacuum transmitting hoses from the vacuum switching valve assembly and turbo pressure sensor.

    2. Disconnect the vacuum hose from the EGR with cooler pipe assembly.

    3. Disconnect the No. 2 oil cooler hose from the EGR with cooler pipe assembly.

    4. Disconnect the No. 2 water by-pass hose from the EGR with cooler pipe assembly.

    5. A236377

      Remove the 4 bolts, 2 nuts and EGR with cooler pipe assembly.

    6. Remove the 2 gaskets from the cylinder head sub-assembly and electric EGR control valve assembly.

  5. REMOVE NO. 1 EGR COOLER BRACKET

    1. A256563

      Remove the 2 bolts and No. 1 EGR cooler bracket from the cylinder head sub-assembly.

  6. REMOVE HARNESS BRACKET

    Click hereClick here

  7. REMOVE EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    Click here

  8. REMOVE ENGINE OIL LEVEL DIPSTICK

    1. Remove the engine oil level dipstick.

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    1. A205719

      Remove the bolt and engine oil level dipstick guide.

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

  10. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

    1. A296840

      Disconnect the vacuum transmitting hose from the hose clamp.

    2. Remove the 2 bolts, 2 nuts and intake air connector with diesel throttle body.

    3. Remove the intake air connector gasket from the cylinder head sub-assembly.

  11. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

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  12. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

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  13. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 1 GLOW PLUG CONNECTOR

    1. Remove the 4 screw grommets.

    2. A204100

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

  15. REMOVE GLOW PLUG ASSEMBLY

    1. A204101

      Remove the 4 glow plug assemblies.

  16. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

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  17. REMOVE NOZZLE LEAKAGE PIPE SET CLAMP

    1. A198350

      Remove the 3 nozzle leakage pipe set clamps from the nozzle leakage pipe assembly.

  18. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    1. A194598

      Remove the retainer spring and disconnect the nozzle leakage pipe assembly from the supply pump assembly.

    2. A199739C03

      *a

      Lock Bush

      Pull up the lock bush as shown in the illustration and remove the nozzle leakage pipe assembly.

      Note:

      Do not remove the nozzle leakage pipe assembly by pulling the hose. Remove it by holding the lock bush.

  19. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    Click here

  20. REMOVE NOZZLE HOLDER CLAMP SEAT

    Click here

  21. REMOVE INJECTOR ASSEMBLY

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  22. REMOVE INJECTION NOZZLE SEAT

    Click here

  23. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  24. REMOVE NO. 2 FUEL HOSE

    1. A204609

      Remove the No. 2 fuel hose.

  25. REMOVE SUPPLY PUMP ASSEMBLY

    1. A237299

      Disconnect the No. 1 fuel hose from the supply pump assembly.

    2. A196505

      Remove the 3 bolts and supply pump assembly.

    3. A202920

      Remove the O-ring from the supply pump assembly.

  26. REMOVE NO. 1 SUPPLY PUMP DRIVE COUPLING

    Click here

  27. REMOVE COMMON RAIL ASSEMBLY

    1. A205792

      Remove the 2 bolts and common rail assembly from the cylinder head sub-assembly.

      Note:

      Do not remove the fuel pressure sensor and fuel pressure regulator.

  28. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    1. A295957

      Remove the No. 1 intake manifold insulator.

  29. REMOVE NO. 2 CYLINDER HEAD COVER

    1. A205711

      Remove the No. 2 cylinder head cover.

  30. REMOVE OIL COOLER HOSE

    1. A202767

      Remove the oil cooler hose.

  31. REMOVE NO. 2 OIL COOLER HOSE

    1. A296841

      Remove the 2 hose clamps.

    2. A296842

      Disconnect the 2 hose clamps and remove the No. 2 oil cooler hose.

  32. REMOVE NO. 4 WATER BY-PASS HOSE

    1. A250689

      Remove the No. 4 water by-pass hose from the inlet water pipe.

  33. REMOVE NO. 3 WATER BY-PASS HOSE

    1. A250690

      Remove the No. 3 water by-pass hose from the water by-pass pipe sub-assembly.

  34. REMOVE NO. 2 WATER BY-PASS HOSE

    1. A250691

      Remove the No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

  35. REMOVE WATER BY-PASS HOSE

    1. A250806

      Remove the water by-pass hose.

  36. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    1. A296843

      Remove the 2 hose clamps from the water by-pass pipe sub-assembly.

    2. A250707

      Remove the 2 bolts and water by-pass pipe sub-assembly.

    3. Remove the O-ring from the water by-pass pipe sub-assembly.

  37. REMOVE INLET WATER HOSE RH

    1. A250683

      Remove the inlet water hose RH.

  38. REMOVE INLET WATER HOSE LH

    1. A250698

      Remove the inlet water hose LH.

  39. REMOVE INLET WATER PIPE

    1. A250808

      Remove the 2 bolts and inlet water pipe from the cylinder head sub-assembly.

  40. REMOVE VACUUM PUMP ASSEMBLY

    1. A210143

      Remove the 2 bolts and vacuum pump assembly.

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

  41. REMOVE CAMSHAFT POSITION SENSOR

    1. A297809C01

      *A

      w/o Stop And Start System

      *B

      w/ Stop And Start System

      Remove the bolt and camshaft position sensor.

  42. REMOVE HOLE PLUG

    1. A297810C01

      *A

      w/ Stop And Start System

      *B

      w/o Stop And Start System

      Remove the bolt and hole plug.

  43. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    1. A200038

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

  44. REMOVE HARNESS BRACKET

    1. A205794

      Remove the 2 bolts and 2 harness brackets.

  45. REMOVE NO. 5 ENGINE COVER

    1. A200104

      Remove the 2 bolts, 2 washer plates and No. 5 engine cover.

  46. REMOVE NO. 2 OIL PAN COVER SILENCER

    1. A200105

      Remove the 2 bolts, 2 washer plates and No. 2 oil pan cover silencer.

  47. REMOVE OIL PAN COVER

    1. A200041

      Remove the 2 bolts, 2 washer plates and oil pan cover.

  48. REMOVE STUD BOLT

    1. A296474

      Using an 8 mm socket wrench, remove the 2 stud bolts from the engine mounting bracket RH.