Engine Unit Removal

Remove the 3 bolts and vacuum pump.

Remove the 2 O-rings.

Remove the 2 bolts and No. 1 engine oil level dipstick guide.

Remove the O-ring from the No. 1 engine oil level dipstick.

Disconnect the 4 connectors.

Using a clip remover, detach the 5 wire harness clamps.

Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.

Remove the nut and bolt, and disconnect the generator positive (+) cable.

Remove the 3 bolts, 2 nuts and generator.

Disconnect the hose.

Detach the clamp and remove the breather plug RH.

Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

Disconnect the water hose.

Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.

Remove the 2 bolts and No. 1 turbocharger stay.

Disconnect the hose.

Remove the union bolt, bolt, No. 1 ventilation tube and gasket.

Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.

Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.

Remove the gasket.

w/ DPF:
Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.

Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.

Remove the gasket from the No. 1 turbocharger.

Disconnect the hose.

w/o DPF:
Detach the clamp.

Remove the breather plug LH.

Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.

Remove the front water by-pass joint and gasket.

Disconnect the water hose.

Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.

Remove the 2 bolts and No. 2 turbocharger stay.

Disconnect the hose.

Remove the union bolt, bolt, No. 2 ventilation tube and gasket.

Disconnect the 2 connectors from the turbocharger.

Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.

Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.

Remove the gasket.

w/ DPF:
Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.

Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

Remove the gasket from the turbocharger.

Disconnect the connector and detach the clamp.

Using pliers, grip the claws of the clips and slide the 2 clips.

Disconnect the 2 heater hoses.

Remove the 2 bolts and heater assembly.

Remove the bolt and No. 1 idler pulley bracket.

Disconnect the No. 2 oil cooler hose from the water pump and clamp.

Remove the 4 bolts and water inlet.

Remove the thermostat.

Remove the gasket from the thermostat.

w/o Viscous Heater:
Remove the 2 bolts and timing gear cover insulator.

w/ Viscous Heater:
Remove the timing gear cover insulator.

Remove the 3 bolts and V-ribbed belt tensioner bracket.

Remove the bolt and No. 1 idler pulley.

Remove the 5 bolts and V-ribbed belt tensioner.

Detach the harness clamp and disconnect the wire harness.

Disconnect the starter connector.

Remove the nut and disconnect the starter wire.

Disconnect the 2 starter hoses.

Remove the 2 bolts and starter.

Remove the 2 bolts and starter hose bracket.

Disconnect the sensor connector.

Using a 19 mm deep socket wrench, remove the sensor and gasket.

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

Remove the 2 bolts and gasket and disconnect the water outlet from the No. 2 water hose joint.

Remove the 4 bolts, water outlet pipe and 2 gaskets.

Remove the 2 bolts and No. 1 water outlet pipe from the No. 2 water outlet pipe.

Disconnect the No. 2 water outlet pipe from the No. 1 water hose joint.

Disconnect the water by-pass outlet from the No. 1 water hose joint.

Remove the 2 bolts and clutch flexible hose bracket.

Remove the 2 screw grommets and 2 nuts, and disconnect the 2 wire harnesses.

Remove the 8 screw grommets, 8 nuts and 2 glow plug connectors.

Using a 10 mm deep socket wrench, remove the 8 glow plugs.

HINT:

Before removing the glow plugs, thoroughly clean off all dirt, sand, etc.

Disconnect the 2 connectors and remove the bolt and fuel pump motor wire.

Remove the bolt, cover, No. 2 idler pulley and collar.

Remove the 3 bolts and idler pulley bracket.

Remove the 4 bolts and fan bracket.

Disconnect the 2 vacuum hoses.

Remove the bolt and vacuum switching valve.

w/ Intercooler:
Disconnect the 2 vacuum hoses.

Remove the 3 bolts and vacuum transmitting pipe.

w/ Intercooler:
Remove the 3 bolts and cylinder head cover silencer RH.

w/ Intercooler:
Remove the 3 bolts and cylinder head cover silencer LH.

Remove the 2 bolts, rear cylinder head plate RH and gasket.

Remove the 2 bolts, rear cylinder head plate LH and gasket.

Remove the 2 bolts and No. 1 intake air connector bracket.

Remove the 2 bolts and air tube support.

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

Disconnect the vacuum hose.

Remove the 2 bolts and No. 4 vacuum transmitting pipe.

Remove the 4 bolts and engine mounting bracket RH.

Detach the 2 wire harness clamps.

Remove the bolt and No. 2 intake air connector bracket.

Detach the 3 wire harness clamps.

Remove the 2 bolts and turbocharger wire.

w/ Intercooler:
Disconnect the vacuum hose.

Remove the 2 bolts and No. 3 vacuum transmitting pipe.

Remove the union bolt, 2 bolts, No. 2 water by-pass pipe and gasket.

Remove the 4 bolts and engine mounting bracket LH.

Remove the bolt and oil tank bracket.

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

Remove the 2 bolts and No. 3 engine hanger.

Remove the oil filter drain cock plug.

Remove the oil filter drain cock body.

HINT:

If the drain cock is deformed or clogged, replace or repair it.

Using a 26 mm wrench, remove the oil pressure regulator and gasket.

Remove the O-ring from the oil pressure regulator body.

Hold the oil pressure regulator body in a vise between aluminum plates.

NOTICE:

Be careful not to damage the oil pressure regulator body.

Using a 10 mm hexagon wrench, remove the oil pump relief valve plug labeled A and gasket.

CAUTION:

When removing the plug, be careful as the spring will be jumped out.

Remove the 2 springs labeled B.

Remove the oil pump relief valve labeled C.

Remove the 2 bolts and stiffener insulator RH.

Align the timing mark of the crankshaft pulley and the chain cover and compressor bracket.

Remove the bolt and compressor bracket.

Disconnect the 2 exhaust fuel addition injector connectors.

Remove the 2 bolts, 2 washers and 2 nozzle holder clamps.

Remove the 2 exhaust fuel addition injectors and 2 gaskets.

Remove the 2 fuel injector seals.

Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

Install 8 10 mm x 1.25 pitch bolts with a length of 70 mm or more to the flywheel.

Uniformly tighten the 8 bolts in the order shown in the illustration.

Remove the ring gear from the flywheel.

Using a torch, heat a new ring gear evenly to approximately 200°C (392°F).

NOTICE:

Be careful not to overheat the ring gear.

Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.

NOTICE:

1. Make sure to press in the ring gear until the ring gear contacts the flywheel, as shown in A in the illustration.
   
2. After installing, allow the ring gear to cool before handling.
   

Replace the flywheel straight pin.