Engine Assembly Removal

Disconnect the washer nozzle hose.

Remove the 4 bolts and hood.

Remove the oil filler cap.

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

Wipe the oil pan and drain plug.

Install a new gasket and the oil pan drain plug.

Torque:

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

Loosen the radiator drain cock plug.

HINT:

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

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

Loosen the cylinder block drain cock plug.

Remove the drain plug and gasket to drain the oil.

Install a new gasket and the drain plug.

Torque:

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

Remove the bolt, nut and battery clamp.

Disconnect the mass air flow meter connector.

Loosen the hose clamp.

Remove the 2 bolts and air cleaner.

Remove the 3 bolts, 2 cap nuts and No. 1 engine cover.

Text in Illustration

Cap Nut

Disconnect the 2 heater hoses.

Disconnect the oil reservoir to pump hose.

Disconnect the pressure feed tube.

Disconnect the 2 fuel hoses.

Disconnect the union to connector tube hose.

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.

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

Remove the upper relay block cover.

Remove the side relay block cover.

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

Disconnect the 2 engine room junction block connectors.

Remove the bolt and disconnect the ground cable.

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

Disconnect the 3 injector driver connectors.

Disconnect the turbo motor driver connector.

Disconnect the 4 ECM connectors.

Remove the 4 bolts and disconnect the cooler compressor.

HINT:

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

Place matchmarks on the clutch cover and flywheel.

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

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

NOTICE:

Do not drop the clutch disc.

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

Remove the 8 bolts and flywheel.

Remove the bolt and rear end plate.

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:

60 N*m{612 kgf*cm, 44 ft.*lbf}

NOTICE:

Install the engine hangers with new bolts.

HINT:

Part No.

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

Remove the 4 bolts and 4 nuts.

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

Install the engine to an engine stand with the bolts.

Remove the 2 bolts and 2 engine hangers.

Remove the engine wire from the engine.

Remove the 2 nuts and 2 front engine mounting insulators.

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

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

HINT:

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.

HINT:

1. If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
2. When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.
   

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

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

SST

09213-58014
09330-00021

Using SST, remove the pulley bolt and crankshaft pulley.

SST

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

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

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

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

Remove the nut and generator wire.

Disconnect the generator connector.

Remove the 2 bolts and generator.

Remove the bolt and generator bracket.

Remove the 4 bolts and V-ribbed belt tensioner.

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

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

Remove the gasket.

Disconnect the wire harness clamp.

Remove the 3 bolts and water inlet.

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

Remove the thermostat from the cylinder block.

Remove the gasket from the thermostat.

Remove the 2 bolts, water outlet and gasket.

Disconnect the 2 connectors.

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

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

Using SST, remove the oil filter.

SST

09228-07501

HINT:

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

Disconnect the 2 connectors.

Remove the 2 bolts, common rail and No. 2 intake manifold insulator.

NOTICE:

Do not remove the pressure discharge valve or pressure sensor.

Disconnect the 2 fuel hoses.

Disconnect the fuel temperature sensor connector and suction control valve connector.

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

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

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

SST

09213-58014
09330-00021

Loosen the 2 nuts.

Using SST, disconnect the fuel supply pump from the injection gear.

SST

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

NOTICE:

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

Remove the 2 nuts and fuel supply pump.

NOTICE:

1. Do not hold or carry the fuel supply pump by the pipe.
   
2. The fuel supply pump must be kept horizontal.
   

Remove the O-ring.

Disconnect the oil pressure switch connector.

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

Remove the 13 bolts, oil cooler cover and gasket.

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

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

Disconnect the crankshaft position sensor connector.

Detach the 4 clips and remove the bolt and crankshaft position sensor.

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor.

Disconnect the engine coolant temperature sensor connector.

Remove the engine coolant temperature sensor.

Remove the gasket from the engine coolant temperature sensor.

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

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