ENGINE ASSEMBLY (w/o DPF) 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. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


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

  5. REMOVE NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 6 bolts and No. 2 engine under cover.

  6. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly 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.

      B007OT1E01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block drain cock plug (on the engine oil cooler cover), and drain the engine coolant.

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  7. 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 oil pan drain plug.

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

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

  8. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and drain the oil.

    3. Install the drain plug with a new gasket.

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

  9. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


    1. B007R03E01

      Remove the drain plug and gasket and drain automatic transmission fluid.

    2. Install the drain plug with a new gasket.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  10. REMOVE FRONT SEAT ASSEMBLY RH


    1. B007T2L

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  11. REMOVE FRONT DOOR SCUFF PLATE RH

  12. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet and remove the engine service hole sub cover.

  13. REMOVE NO. 2 ENGINE SERVICE HOLE COVER (for Standard Body)


    1. Detach the clips and fold back the carpet.

    2. B007TSQ

      Remove the 3 bolts and No. 2 engine service hole cover.

  14. REMOVE FAN AND GENERATOR V BELT


    1. B007OR0E01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  15. REMOVE FAN PULLEY


    1. Remove the 4 nuts and fan pulley.

  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  17. REMOVE NO. 1 AIR CLEANER HOSE


    1. B007OVI

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  18. REMOVE AIR TUBE ASSEMBLY


    1. B007VEO

      Loosen the 2 hose clamps.

    2. Remove the 2 bolts, air tube assembly and No. 1 air cleaner hose.

  19. REMOVE COMPRESSOR OUTLET ELBOW


    1. B007P7D

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

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


    1. B007S7ZE01

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

  21. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


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

  22. REMOVE GENERATOR ASSEMBLY

    Click here

  23. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B007UVH

      Remove the 4 bolts and V-ribbed belt tensioner.

  24. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  25. REMOVE EXHAUST MANIFOLD


    1. B007QBL

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

  26. DISCONNECT OIL RETURN HOSE


    1. Disconnect the oil return hose from the intake manifold.

  27. REMOVE NO. 4 AIR HOSE


    1. Remove the No. 4 air hose from the diesel throttle body.

  28. DISCONNECT RADIATOR HOSE INLET


    1. Disconnect the radiator hose inlet from the water outlet.

  29. DISCONNECT NO. 4 RADIATOR HOSE


    1. Disconnect the No. 4 radiator hose from the water inlet.

  30. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. Disconnect the No. 3 water by-pass hose from the No. 2 water by-pass pipe.

  31. DISCONNECT NO. 2 FUEL HOSE


    1. Disconnect the No. 2 fuel hose from the No. 2 nozzle leakage pipe.

  32. DISCONNECT NO. 1 FUEL HOSE


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

  33. DISCONNECT VACUUM HOSE


    1. B007RL5E01

      Disconnect the vacuum hose from the vacuum pump.

  34. DISCONNECT ENGINE WIRE


    1. B007VHM

      Remove the bolt.

    2. B007QCA

      Disconnect the ECM connector Click here.

    3. Disconnect the 4 connectors.

    4. Detach the 3 clamps.

  35. DISCONNECT ENGINE ROOM MAIN WIRE


    1. B007U4J

      Disconnect the 5 connectors.

    2. B007R4I

      Open the cover and remove the nut.

    3. B007POQ

      Detach the clamp and disconnect the engine room main wire.

  36. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. B007UZF

      Remove the 2 bolts and disconnect the vane pump oil reservoir.

  37. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

  38. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  39. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. B007VZ5E01

      Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

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

    3. Remove the set bolts, and pull off the clutch cover assembly.

      Note

      Do not drop the clutch disc assembly.

  40. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note

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

  41. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. B007RCAE03

      Hold the crankshaft pulley with SST.

      SST
      09213-58014
      09330-00021
    2. B007OCUE01

      for Manual Transmission:

      Remove the 8 bolts and flywheel.

    3. for Automatic Transmission:

      Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel.

  42. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  43. REMOVE SPEED SENSOR FRONT LH (w/ ABS)


    1. B007P1BE01

      Remove the 2 bolts, and separate the speed sensor from the steering knuckle.

      Note


      • Be careful not to damage the speed sensor.

      • Prevent foreign matter from adhering to the speed sensor.

  44. REMOVE SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  45. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. B007U9LE01

      Remove the 2 bolts, and disconnect the brake caliper assembly.

      Note

      Use a wire or an equivalent to keep the brake caliper from hanging down by the flexible hose.

  46. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  47. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. B007R55E01

      Remove the cotter pin and loosen the nut.

      SST
      09628-62011

      Note

      Do not remove the nut.

    2. Using SST, separate the steering knuckle from the suspension upper arm and remove the nut.

      Note


      • Fix the steering knuckle with a wire so that the flexible hose does not receive excessive force.

      • Do not damage the ball joint dust cover.

  48. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  49. DISCONNECT SHOCK ABSORBER ASSEMBLY FRONT LH


    1. B007V39E02

      Remove the bolt and separate the front shock absorber from the front suspension lower arm.

  50. DISCONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  51. DISCONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. B007UQIE01

      Loosen bolt (A) and remove bolt (B), then slide the steering torque shaft assembly.

      Tech Tips


      • Do not remove bolt (A).

      • Do not disconnect the steering torque shaft assembly from the power steering link assembly.

    2. B007RMBE01

      Put matchmarks on the steering torque shaft assembly and the power steering link assembly.

    3. Separate the steering torque shaft assembly from the power steering link assembly.

  52. REMOVE ENGINE ASSEMBLY


    1. Set an engine lifter in place.

    2. B007U2VE02

      Remove the 16 bolts as shown in the illustration.

    3. Operate the engine lifter and slowly remove the engine from the vehicle.

  53. INSTALL ENGINE HANGERS


    1. B007ORME01

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Tech Tips

      Part No.

      No. 1 Engine Hanger 12284-30020
      No. 2 Engine Hanger 12282-67020
      Bolt 91552-81014 and 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.

  54. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE


    1. B007SXDE01

      Remove the clip and separate the No.1 oil reservoir to pump hose.

  55. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. B007SOCE01

      Remove the union bolt and separate the pressure feed tube assembly.

  56. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Hold the engine with an engine sling device and chain block.

    2. Remove the 4 bolts and front suspension crossmember.

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

  57. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. Remove the 2 nuts, 2 engine mounting stabilizers and 2 front engine mounting insulators.

  58. INSTALL ENGINE TO ENGINE STAND

  59. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  60. REMOVE VANE PUMP ASSEMBLY


    1. B007QBUE01

      Remove the 2 nuts and the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  61. REMOVE TIMING GEAR COVER INSULATOR


    1. B007RND

      Remove the bolt and timing gear cover insulator.

  62. REMOVE VACUUM PUMP ASSEMBLY


    1. B007QFB

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

  63. REMOVE TIMING BELT

    Click here

  64. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. B007VP8E01

      Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  65. REMOVE CRANKSHAFT POSITION SENSOR

    B007VEA

    1. Disconnect the crankshaft position sensor connector.

    2. Separate the connector from the No. 1 vacuum pipe .

    3. B007OTL

      Separate the 3 wire harness clamps.

    4. Remove the bolt and the crankshaft position sensor.

  66. REMOVE CAMSHAFT POSITION SENSOR

    B007VA3

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  67. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. w/o DPF:


      1. B007U29

        Disconnect the diesel turbo pressure sensor connector and vacuum switching valve connector.

      2. Remove the bolt and disconnect the wire harness clamp.

    2. Disconnect the 2 diesel throttle body connectors.

    3. B007TF0E01

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

  68. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  69. REMOVE EGR COOLER ASSEMBLY

    Click here

  70. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. B007U0B

      Disconnect the vacuum switching valve connector and 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve bracket.

  71. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B007ROT

      Disconnect the 3 fuel hoses.

    2. B007V57E01

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

  72. REMOVE COMMON RAIL ASSEMBLY

    Click here

  73. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  74. REMOVE CRANKSHAFT PULLEY


    1. B007T0QE01

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. B007R5AE01

      Using SST, remove the 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.

  75. REMOVE NO. 2 WATER BY-PASS PIPE


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

    2. Remove the gasket.

  76. REMOVE WATER INLET


    1. B007VIT

      Remove the 3 bolts and water inlet.

  77. REMOVE THERMOSTAT


    1. Remove thermostat and gasket.

  78. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

  79. REMOVE GLOW PLUG ASSEMBLY

    Click here

  80. REMOVE MANIFOLD STAY


    1. B007QXUE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and manifold stay.

  81. REMOVE INTAKE MANIFOLD


    1. B007TI0

      Remove the 4 bolts, 2 nuts and intake manifold.

    2. Remove the gasket.

  82. REMOVE WATER OUTLET


    1. Remove the 2 bolts, water outlet and gasket.

  83. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Disconnect the vacuum hose.

    2. Remove the bolt, nut and No. 1 vacuum transmitting pipe.

  84. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Remove the bolt, 2 nuts and No. 2 vacuum transmitting pipe.

  85. REMOVE OIL COOLER COVER SUB-ASSEMBLY

    Click here

  86. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B007V7E

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

  87. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. B007RTG

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