ENGINE ASSEMBLY (for DPF) REMOVAL

Note


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

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

  • After removing the injection pipe sub-assemblies, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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 sub-assembly.

  3. REMOVE NO. 1 ENGINE UNDER COVER

  4. REMOVE NO. 2 ENGINE UNDER COVER

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  6. DRAIN ENGINE COOLANT

    CAUTION:

    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. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A01DY58E01

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

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  7. DRAIN TRANSMISSION OIL


    1. Remove the drain plug and gasket to drain the oil.

    2. Install a new gasket and the drain plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  8. DRAIN POWER STEERING FLUID

  9. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. Remove the bolt, nut and battery clamp sub-assembly.

  10. REMOVE BATTERY

  11. REMOVE BATTERY TRAY

  12. REMOVE AIR CLEANER ASSEMBLY


    1. A01E1IB

      Detach the wire harness clamp and disconnect the mass air flow meter connector.

    2. Loosen the hose clamp and disconnect No. 1 air cleaner hose from the compressor inlet elbow.

    3. Remove the 2 bolts and air cleaner assembly together with the No. 1 air cleaner hose.

  13. REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

    Click here

  14. REMOVE RADIATOR ASSEMBLY

    Click here

  15. REMOVE STARTER ASSEMBLY


  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  17. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

    A01DWR8E01

    1. Place matchmarks on the propeller shaft flange and differential flange.

    2. Remove the 4 nuts, 4 bolts and 4 washers, and disconnect the propeller shaft.

    3. A01DYY7E01

      Place matchmarks on the propeller shaft flange and transfer flange.

    4. Remove the 4 nuts, 4 washers and front propeller shaft.

  18. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  19. DISCONNECT HEATER HOSE


    1. A01DVYM

      Slide the 2 clamps and disconnect the 2 heater hoses from the water outlet and heater pipe.

  20. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. A01E19T

      Slide the clamp and disconnect the oil reservoir to pump hose from the vane pump assembly.

    2. A01E1EI

      Disconnect the pressure feed tube assembly from the vane pump assembly.

  21. DISCONNECT FUEL HOSE


    1. A01DVVB

      Slide the 2 clamps and disconnect the 2 fuel hoses from the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly.

  22. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01DZ0B

      Slide the clamps and disconnect the union to connector tube hose from the No. 1 hose to hose tube.

  23. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  24. 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. Disconnect the 4 glow plug controller connectors.

    8. Disconnect the 4 injector driver connectors.

    9. A01DZMFE01
      Text in Illustration
      *A for LHD
      *B for RHD

      for 4WD:

      Disconnect the 4WD control ECU connector.

    10. Disconnect the 6 ECM connectors.

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


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

      Tech Tips

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

  26. REMOVE MANUAL TRANSMISSION ASSEMBLY


  27. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Remove the 4 bolts and rear No. 1 engine mounting insulator.

  28. 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.

  29. 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.

  30. 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 sub-assembly.

  31. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  32. INSTALL ENGINE HANGERS


    1. A01E1IIE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

      Tech Tips

      Part No.

      No. 1 Engine Hanger 12284-30020
      No. 2 Engine Hanger 12282-67030
      Bolt 91552-81014 and 91642-81030

      Note

      Install the engine hangers with new bolts.

  33. REMOVE ENGINE ASSEMBLY


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

    2. A01DXM6E01

      Remove the 4 bolts and 4 nuts.

    3. Remove the engine assembly by operating the engine sling device and chain block.

  34. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand with bolts.

    2. Remove the 2 bolts and 2 engine hangers.

  35. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  36. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01DZITE02
      Text in Illustration
      *A RH Side
      *B LH Side

      Remove the 2 nuts and 2 front engine mounting insulators.

  37. REMOVE NO. 1 TIMING BELT COVER


    1. A01E1VTE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  38. REMOVE TIMING BELT


    1. A01DWQTE05
      Text in Illustration
      *1 Timing Mark

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

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A01E0E0E01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A01DYCXE02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.

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

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  40. REMOVE CRANKSHAFT PULLEY


    1. A01E21RE01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01E046E01

      Using SST, remove the pulley bolt and crankshaft 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.

  41. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET


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

  42. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET


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

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

    Click here

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


    1. Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly.

  45. REMOVE NO. 2 IDLE PULLEY ASSEMBLY


    1. Remove the bolt, pulley plate, No. 2 idle pulley assembly and spacer.

  46. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  47. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  48. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner assembly.

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


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

  50. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  51. REMOVE EXHAUST MANIFOLD


    1. A01DXWR

      Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

    2. Remove the gasket.

  52. REMOVE WATER INLET

    A01DVAU

    1. Disconnect the wire harness clamp.

    2. Remove the 3 bolts and water inlet.

    3. Remove the bolt and wire harness clamp bracket from the water inlet.

  53. REMOVE THERMOSTAT


    1. Remove the thermostat from the cylinder block.

    2. Remove the gasket from the thermostat.

  54. REMOVE WATER OUTLET


    1. A01DY53

      Remove the 2 bolts, water outlet and gasket.

  55. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DZIZ

      Disconnect the 2 connectors.

    2. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  56. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  57. REMOVE INTAKE MANIFOLD

    Click here

  58. REMOVE GLOW PLUG ASSEMBLY

    Click here

  59. REMOVE FUEL HOSE PROTECTOR


    1. A01E20Y

      Remove the bolt, nut and fuel hose protector.

  60. REMOVE NO. 1 FUEL PIPE


    1. A01DUZK

      Remove the No. 1 fuel pipe from the fuel hose bracket.

  61. REMOVE FUEL HOSE BRACKET


    1. A01DY4A

      Remove the bolt and fuel hose bracket.

  62. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DYHFE01

      Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

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

  63. REMOVE COMMON RAIL ASSEMBLY

    Click here

  64. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  65. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. Disconnect the oil pressure switch connector.

    2. Remove the 2 nuts and disconnect the No. 2 vacuum transmitting pipe from the oil cooler cover.

    3. A01E05LE01

      Remove the 13 bolts, oil cooler cover and gasket.

  66. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DVEJE01

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

  67. REMOVE VANE PUMP ASSEMBLY


    1. A01E0JL

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

  68. REMOVE CRANKSHAFT POSITION SENSOR

    A01DZC3

    1. Disconnect the sensor connector.

    2. Remove the 3 clips, bolt and sensor.

  69. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DY98

      Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  70. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01DWMB

      Disconnect the sensor connector.

    2. Remove the sensor.

    3. Remove the gasket from the sensor.

  71. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01DYBQE02
      Text in Illustration
      *A RH Side
      *B LH Side

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

  72. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


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