ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01OADF

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  2. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01OBR6

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

    2. Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.

  3. REMOVE EGR VALVE BRACKET

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  4. REMOVE EGR COOLER ASSEMBLY

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  5. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01ODTJ

      Remove the 2 bolts and No. 2 water by-pass pipe from the cylinder head sub-assembly.

  6. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01OCY6C01
      *1 No. 13 Water By-pass Hose
      *2 No. 3 Water By-pass Pipe

      Slide the clip and disconnect the No. 13 water by-pass hose from the water outlet sub-assembly.

    2. Remove the 3 bolts and No. 3 water by-pass pipe from the cylinder block sub-assembly.

  7. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01OC6C

      Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.

  8. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01O9E0

      Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

  9. REMOVE IGNITION COIL ASSEMBLY

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  10. REMOVE ENGINE COVER JOINT


    1. A01O99H

      Remove the 3 engine cover joints from the cylinder head cover sub-assembly.

  11. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01OC3O

      Remove the 9 bolts and 7 wire harness clamp brackets.

  12. REMOVE ENGINE WATER PUMP ASSEMBLY

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  13. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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  14. REMOVE NO. 5 WATER BY-PASS PIPE


    1. A01OB2KC01
      *1 No. 11 Water By-pass Hose
      *2 No. 5 Water By-pass Pipe

      Slide the clip and disconnect the No. 11 water by-pass hose from the water outlet sub-assembly.

    2. Remove the bolt, 2 nuts and No. 5 water by-pass pipe from the water inlet housing.

    3. Remove the gasket from the water inlet housing.

  15. REMOVE WATER INLET HOUSING


    1. A01OC60

      Remove the 2 bolts, nut and water inlet housing from the cylinder block sub-assembly.

    2. Remove the gasket from the water inlet housing.

      Note

      If a stud bolt is deformed or its threads are damaged, replace it.

  16. REMOVE NO. 1 FUEL PIPE

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  17. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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  18. REMOVE FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  19. REMOVE FUEL DELIVERY PIPE

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  20. REMOVE FUEL INJECTOR ASSEMBLY

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  21. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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  22. REMOVE FUEL INJECTOR SET

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  23. REMOVE FUEL INJECTOR SEAL

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  24. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  25. REMOVE WATER OUTLET SUB-ASSEMBLY

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