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.
After removing the injection pipes, clean them with a brush and compressed air.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE NO. 1 ENGINE UNDER COVER
DRAIN ENGINE COOLANT
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.
Loosen the radiator drain cock plug.
Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
Loosen the cylinder block drain cock plug.
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER
REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY
Remove the bolt, nut and 2 No. 2 injection pipe clamps.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
Remove the 3 bolts and No. 2 cylinder head cover.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.
Disconnect the ventilation hose.
Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
REMOVE RADIATOR HOSE INLET
REMOVE FAN SHROUD
Remove the 3 bolts and oil reservoir.
Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator.
Remove the 2 bolts and radiator reservoir.
Loosen the 4 nuts holding the fluid coupling with fan.
Remove the fan and generator V belt Click here.
Remove the 2 bolts holding the fan shroud.
Remove the 4 nuts of the fluid coupling with fan, and then remove the fan shroud together with the fluid coupling with fan.
Be careful not to damage the radiator core.
Remove the fan pulley from the water pump.
DISCONNECT COOLER COMPRESSOR ASSEMBLY
Remove the 4 bolts and disconnect the cooler compressor.
It is not necessary to completely remove the cooler compressor. With the hoses connected to the cooler compressor, hang the cooler compressor on the vehicle body with a rope.
REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)
REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)
Remove the 4 bolts and No. 1 viscous heater bracket.
REMOVE NO. 2 IDLE PULLEY ASSEMBLY
Remove the bolt, pulley plate, No. 2 idle pulley and spacer.
REMOVE GENERATOR ASSEMBLY
Remove the nut and generator wire.
Disconnect the generator connector.
Remove the 2 bolts and generator.
REMOVE GENERATOR BRACKET
Remove the bolt and generator bracket.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
Remove the 4 bolts and V-ribbed belt tensioner.
REMOVE NO. 1 TIMING BELT COVER
Remove the 6 bolts, 6 washers and timing belt cover.
REMOVE TIMING BELT
Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.
Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.
Remove the timing belt.
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.
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.
Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.
REMOVE CAMSHAFT TIMING PULLEY
Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.
Remove the camshaft timing pulley.
REMOVE NO. 2 TIMING BELT COVER
Remove the 4 bolts, nut and No. 2 timing belt cover.
REMOVE CYLINDER BLOCK INSULATOR
Remove the cylinder block insulator from the cylinder head.
REMOVE WATER PUMP ASSEMBLY
Remove the 5 bolts, 2 nuts, water pump and gasket.