ENGINE ASSEMBLY REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. Remove the 4 bolts and hood.

  3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and No. 1 engine under cover.

  4. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)


    1. Remove the 2 bolts and No. 2 engine under cover.

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug, and drain the engine oil from the oil pan.

      Note

      Collect the oil in an oil disposal container.

  6. LOOSEN FUEL TANK CAP ASSEMBLY

  7. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    2. Loosen the cylinder block drain cock plug and the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

      A01DY14E01

  8. REMOVE BATTERY BRACKET

  9. REMOVE BATTERY AND BATTERY TRAY

  10. REMOVE AIR CLEANER ASSEMBLY


    1. for Ventilation Hose Type:

      Disconnect the ventilation hose.

    2. w/ Mass Air Flow Meter:

      Disconnect the mass air flow meter sensor connector.

    3. w/ Intake Air Temperature Sensor:

      Disconnect the intake air temperature sensor connector.

    4. Loosen the hose clamp.

    5. Remove the 2 bolts and air cleaner.

  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ EGR Cooler)


    1. A01E1YJ

      Remove the 3 bolts, 2 nut and engine cover.

  12. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler)


    1. A01DY9J

      Detach the 2 clamps.

    2. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    3. Disconnect the IAT sensor connector and manifold absolute diesel pressure sensor connector.

    4. A01DXPG

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DV5L

      Loosen the 2 hose clamps of the No. 2 air hose.

    6. A01DZT1

      Remove the 4 bolts and intercooler.

  13. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o EGR Cooler)

    A01E0K7

    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose from the gas filter.

    3. Loosen the 2 clamps.

    4. Remove the bolt and disconnect the pipe together with the 2 air hoses.

  14. REMOVE RADIATOR ASSEMBLY

    Click here

  15. DISCONNECT HEATER HOSE


    1. A01DVYM

      Disconnect the 2 heater hoses.

  16. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. A01E19T

      Disconnect the oil reservoir to pump hose.

    2. A01E1EI

      Disconnect the pressure feed tube.

  17. DISCONNECT FUEL HOSE


    1. A01DVVB

      Disconnect the 2 fuel hoses.

  18. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01DZ0B

      Disconnect the union to connector tube hose.

  19. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

    A01DY2GE01
    Text in Illustration
    *1 Stopper

    1. Slightly bend the upper part of the glove compartment door to release the 2 stoppers and open the glove compartment door until it is horizontal.

    2. A01DZ7ME01
      Text in Illustration
      *1 Hinge

      Pull the glove compartment door toward the rear of the vehicle to detach the 2 hinges and remove the glove compartment door.

  20. DISCONNECT WIRE HARNESS

    A01DZDI

    1. Remove the upper relay block cover.

    2. Remove the side relay block cover.

    3. Remove the nut and disconnect the engine room junction block wire.

    4. Disconnect the 2 engine room junction block connectors.

    5. Remove the bolt and disconnect the ground cable.

    6. A01E0PX

      Remove the 2 nuts, detach the clamp and disconnect the wire harness.

    7. A01DZOYE01

      Disconnect the 3 EDU connectors.

    8. A01E0HDE01

      w/ A.D.D.

      Disconnect the 4WD control ECU connector.

    9. Disconnect the 4 ECM connectors.

  21. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Remove the 4 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  22. REMOVE TRANSMISSION ASSEMBLY


  23. REMOVE CLUTCH COVER ASSEMBLY


    1. A01DVT8E01

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  24. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  25. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01E0WNE02

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    2. A01DZ7P

      Remove the 8 bolts and flywheel.

  26. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  27. REMOVE ENGINE ASSEMBLY


    1. A01E1IIE02

      Install a No. 1 engine hanger and No. 2 engine hanger with 2 bolts as shown in the illustration.

      Tech Tips

      Part No.
      No. 1 Engine hanger w/ EGR cooler 12284-30060
      Bolt (91552-81014)
      w/o EGR cooler 12284-30020
      Bolt (91552-81014)
      No. 2 Engine hanger 12282-67030
      Bolt (91642-81030)
      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

    2. Attach an engine sling device and hang the engine with a chain block.

    3. A01E0ZE

      Remove the bolt and No. 2 cylinder block insulator.

    4. A01DXM6E01

      Remove the 4 bolts and 4 nuts.

    5. Remove the engine by operating the engine sling device and chain block.

  28. FIX ENGINE ON ENGINE STAND

  29. REMOVE ENGINE WIRE


    1. Remove the engine wire.

  30. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. A01E0I5

      Remove the 6 bolts and timing belt cover.

  31. REMOVE TIMING BELT


    1. A01DWQTE02

      Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

    2. A01E0E0E01

      Uniformly loosen the 2 bolts and remove the timing belt tensioner.

    3. Remove the timing belt.

    4. Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

      Tech Tips

      A01DW3FE01

      • When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.

      • When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks, as shown in the illustration.

  32. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

  33. REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY

  34. REMOVE CRANKSHAFT PULLEY


    1. A01E1JVE02

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01DWXXE02

      Using SST, remove the pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply oil or grease to the threads and tip of SST (center bolt) before using it.

  35. REMOVE TURBOCHARGER SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  36. REMOVE TURBOCHARGER SUB-ASSEMBLY (w/o EGR Cooler)

    Click here

  37. REMOVE EXHAUST MANIFOLD

    A01DZAUE01

    1. w/o EGR Cooler:

      Remove the 8 nuts, 8 spacers and exhaust manifold.

    2. w/ EGR Cooler:

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

  38. INSPECT EXHAUST MANIFOLD

    A01E1TXE01

    1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage
      0.40 mm (0.0157 in.)

      If the warpage is more than the maximum, replace the exhaust manifold.

  39. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  40. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  41. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner.

  42. REMOVE INTERCOOLER SUPPORT BRACKET (w/ EGR Cooler)


    1. Remove the 2 bolts and intercooler support bracket.

  43. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET (w/ EGR Cooler)


    1. Remove the 2 bolts and No. 2 intercooler support bracket.

  44. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. Remove the 4 bolts and No. 1 compressor mounting bracket.

  45. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)


    1. A01DZH8E02

      Disconnect the connector.

    2. Remove the 2 bolts and viscous with magnet clutch heater assembly.

  46. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. Remove the 4 bolts and No. 1 viscous heater bracket.

  47. REMOVE WATER INLET

    A01DZUQE01

    1. Remove the 3 bolts and water inlet.

  48. REMOVE THERMOSTAT

  49. REMOVE WATER OUTLET


    1. A01DWPOE01

      Remove the 2 bolts and water outlet.

  50. REMOVE GLOW PLUG ASSEMBLY


  51. REMOVE MANIFOLD STAY (w/o EGR Cooler)


    1. A01E344E01

      Remove the 2 bolts and manifold stay.

  52. REMOVE OIL FILTER SUB-ASSEMBLY

    A01DVQRE01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Insert the drain hose in the oil filter. Put the drain oil container beneath the drain hose to collect the oil from the oil filter.

  53. REMOVE INTAKE MANIFOLD (w/ EGR Cooler)

    Click here

  54. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR Cooler)

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01E30RE05

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the 2 nuts and No. 3 injection pipe clamp.

    3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  55. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY (w/o EGR Cooler)


    1. A01E0ZRE01

      Remove the 2 bolts.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01E2XGE01

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  56. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY (w/o EGR Cooler)


    1. Disconnect the 3 fuel hoses.

    2. A01DWIZE03

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

  57. REMOVE INTAKE MANIFOLD (w/o EGR Cooler)


    1. A01E1QP

      Remove the 4 bolts, 2 nuts, intake manifold and gasket.

  58. INSPECT INTAKE MANIFOLD


    1. A01E0ASE01

      Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage
      0.40 mm (0.0157 in.)

      If the warpage is more than the maximum, replace the intake manifold.

  59. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    A01DW6AE01

    1. Remove the bolt and clamp.

    2. Remove the 2 bolts and oil level gauge guide.

    3. A01E03WE07

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

    4. A01DYSWE01

      Disconnect the 2 fuel hoses.

    5. A01DXJEE01

      Disconnect the 2 connectors.

    6. A01E0LPE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    7. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    8. A01E0MBE02

      Remove the set nut and O-ring while holding the crankshaft pulley by using SST.

      SST
      09213-58013
      09330-00021
    9. A01E141E01

      Loosen the 2 nuts.

    10. A01DVLSE01

      Using SST, disconnect the pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    11. Remove the 2 nuts and pump.

      Note


      • Do not hold the pump or carry it holding the pipe.

      • The pump must be kept horizontal.

    12. Remove the O-ring.

  60. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector and pressure discharge valve connector.

    2. A01E2QU

      Remove the 2 bolts and common rail.

      Note

      Do not remove the fuel pressure sensor and pressure discharge valve.

  61. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    A01E05LE01

    1. Disconnect the oil pressure switch connector and wire harness.

    2. Remove the 13 bolts, 2 nuts and oil cooler cover.

  62. REMOVE TIMING GEAR COVER INSULATOR (w/ EGR Cooler)


    1. A01E2IH

      Remove the bolt and timing gear cover insulator.

  63. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DVEJE01

      Remove the 2 nuts, vacuum pump and 2 O-rings.

  64. REMOVE VANE PUMP ASSEMBLY


    1. A01E0JL

      Remove the 2 nuts, vane pump and O-ring.

  65. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and crankshaft position sensor.

  66. REMOVE CAMSHAFT POSITION SENSOR


    1. Remove the bolt and camshaft position sensor.

  67. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.

  68. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01DZITE01

      Remove the 2 nuts and 2 front engine mounting insulators.

  69. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. A01DYBQE01

      Remove the 4 bolts and No. 1 front engine mounting bracket.

  70. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. Remove the 4 bolts and No. 1 front engine mounting bracket.