DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)
DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)
REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)
REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)
Engine Unit -- Removal |
| 1. REMOVE GENERATOR ASSEMBLY |
Remove the 2 bolts and generator.
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| 2. REMOVE GENERATOR BRACKET |
Remove the bolt and generator bracket.
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| 3. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET |
Remove the 5 bolts and No. 1 compressor mounting bracket.
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| 4. REMOVE VENTILATION PIPE |
Type A
Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.
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Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.
Text in Illustration *A Type A *B Type B
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| 5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the engine oil level dipstick.
Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.
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Remove the O-ring from the engine oil level dipstick guide.
| 6. REMOVE COMPRESSOR INLET ELBOW |
Detach the 3 wire harness clamps.
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Remove the bolt and wire harness bracket from the water inlet.
Disconnect the 2 connectors and detach the wire harness clamp.
Text in Illustration *A Type A *B Type B
Slide the clamp and disconnect the No. 2 turbo water hose from the No. 1 turbo water hose sub-assembly.
Slide the clamp and disconnect the No. 3 turbo water hose from the No. 2 water by-pass pipe.
Remove the 2 nuts, compressor inlet elbow and gasket from the turbocharger sub-assembly.
| 7. REMOVE NO. 1 TURBO INSULATOR |
Remove the 2 bolts and No. 1 turbo insulator from the turbocharger sub-assembly.
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| 8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR |
Remove the bolt and No. 1 exhaust manifold heat insulator from the exhaust manifold.
| 9. DISCONNECT NO. 1 TURBO WATER HOSE |
Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.
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| 10. REMOVE TURBINE OUTLET ELBOW |
Remove the 3 nuts, turbine outlet elbow and gasket from the turbocharger sub-assembly.
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| 11. REMOVE TURBOCHARGER STAY |
Remove the 2 bolts, nut and turbocharger stay from the turbocharger sub-assembly and cylinder block sub-assembly.
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| 12. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY |
Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets from the turbocharger sub-assembly and cylinder block sub-assembly.
- NOTICE:
- Do not loosen the nut labeled A in the illustration.
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| 13. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER |
Remove the 8 nuts, 8 plate washers and 8 collars from the exhaust manifold with turbocharger sub-assembly.
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Remove the exhaust manifold with turbocharger and gasket.
| 14. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 2 cylinder head cover.
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| 15. REMOVE COMPRESSOR ELBOW STAY |
Remove the 2 bolts and compressor elbow stay.
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| 16. REMOVE WATER INLET |
Remove the 3 bolts and water inlet.
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| 17. REMOVE THERMOSTAT |
Remove the thermostat.
Remove the gasket from the thermostat.
| 18. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY |
Disconnect the 2 hoses.
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Remove the 2 bolts, 2 nuts and No. 2 water by-pass pipe.
| 19. REMOVE ENGINE OIL LEVEL SENSOR |
Remove the 4 bolts and engine oil level sensor.
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Cut away part of the gasket and remove the gasket from the engine oil level sensor.
- HINT:
- Remove only the outer part of the gasket.
| 20. REMOVE TIMING GEAR COVER INSULATOR |
Remove the bolt and gear cover insulator.
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| 21. REMOVE VACUUM PUMP ASSEMBLY |
Remove the 2 nuts, vacuum pump and 2 O-rings.
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| 22. REMOVE VANE PUMP ASSEMBLY |
Remove the 2 nuts, vane pump and O-ring.
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| 23. REMOVE ENGINE COOLANT TEMPERATURE SENSOR |
Disconnect the engine coolant temperature sensor connector.
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Remove the engine coolant temperature sensor.
Remove the gasket from the engine coolant temperature sensor.
| 24. REMOVE CAMSHAFT POSITION SENSOR |
Remove the bolt and camshaft position sensor.
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| 25. REMOVE CRANKSHAFT POSITION SENSOR |
Detach the clamp and remove the bolt and crankshaft position sensor.
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| 26. REMOVE NO. 1 TIMING BELT COVER |
Remove the 6 bolts, 6 washers and timing belt cover.
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| 27. REMOVE TIMING BELT |
Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
Text in Illustration *1 Timing Mark - HINT:
- If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.
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Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.
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Remove the timing belt.
- HINT:
- 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.
| 28. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY |
- NOTICE:
- 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.
| 29. REMOVE CRANKSHAFT PULLEY |
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)
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| 30. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler) |
Remove the clamp.
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Disconnect the No. 3 water by-pass hose from the EGR cooler.
| 31. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler) |
Disconnect the No. 4 water by-pass hose from the EGR cooler.
| 32. REMOVE INJECTION PIPE (w/ EGR System) |
- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating the injector inlet.
Remove the 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a for Injector Side *b for Common Rail Side
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| 33. REMOVE AIR CONNECTOR STAY (w/ EGR System) |
Remove the 3 bolts and air connector stay.
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| 34. REMOVE EGR VALVE BRACKET (w/ EGR System) |
Remove the 2 nuts and EGR valve bracket.
| 35. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System) |
Disconnect the 2 connectors from the electric EGR control valve and E-VRV.
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Detach the wire harness clamp.
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Disconnect the 5 vacuum hoses.
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Remove the bolt and gas filter together with the gas filter bracket.
Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.
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| 36. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ EGR System) |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 37. REMOVE INTAKE AIR CONNECTOR (w/ EGR System) |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 38. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR System with EGR Cooler) |
Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.
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Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.
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Remove the gasket from the cylinder block.
| 39. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler) |
Remove the 2 nuts and electric EGR control valve together with the No. 1 EGR pipe and gasket.
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| 40. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System) |
Remove the 2 bolts, electric EGR control valve and gasket.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler
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| 41. REMOVE EGR VALVE ADAPTER (w/ EGR System with EGR Cooler) |
Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.
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| 42. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler) |
Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.
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| 43. REMOVE THROTTLE BODY BRACKET (w/o EGR System) |
Disconnect the vacuum hose.
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Remove the bolt and gas filter with gas filter bracket.
Remove the 2 bolts and throttle body bracket.
| 44. REMOVE INJECTION PIPE (w/o EGR System) |
- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating the injector inlet.
Remove the 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a for Injector Side *b for Common Rail Side
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| 45. REMOVE AIR CONNECTOR STAY (w/o EGR System) |
Remove the 3 bolts and air connector stay.
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| 46. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/o EGR System) |
Remove the 3 nuts.
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Remove the No. 2 intake air connector, No. 1 intake air connector and 2 gaskets.
| 47. REMOVE INTAKE AIR CONNECTOR (w/o EGR System) |
Remove the 3 bolts, intake air connector and gasket.
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| 48. REMOVE NO. 2 EGR HOLE COVER PLATE (w/o EGR System) |
Remove the 2 nut, gasket and No. 2 EGR hole cover plate.
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| 49. REMOVE WATER OUTLET |
Remove the 2 bolts, gasket and water outlet.
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| 50. REMOVE NO. 1 GLOW PLUG CONNECTOR |
Remove the 4 screw grommets, 4 nuts and No. 1 glow plug connector.
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| 51. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR |
Remove the No. 1 intake manifold insulator.
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| 52. REMOVE GLOW PLUG ASSEMBLY |
Using a 12 mm deep socket wrench, remove the 4 glow plugs.
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| 53. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE |
Disconnect the No. 1 vacuum transmitting hose.
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w/ EGR System:
Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose assembly.
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w/ EGR Cooler:
Disconnect the No. 3 vacuum transmitting hose.
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Disconnect the No. 3 vacuum transmitting hose assembly and No. 4 vacuum transmitting hose assembly.
Text in Illustration *A w/o EGR System *B w/ EGR System
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Remove the 2 bolts and manifold stay with vacuum switching valve.
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| 54. REMOVE INTAKE PIPE STAY |
Remove the bolt and intake pipe stay.
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| 55. REMOVE VACUUM CONTROL VALVE SET |
Disconnect the 2 VSV connectors and 3 vacuum hoses.
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Remove the 2 bolts and vacuum control valve set.
| 56. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt and detach the injection pipe clamp.
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
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| 57. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 3 fuel hoses.
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Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.
Text in Illustration *1 Union Bolt
| 58. REMOVE INTAKE MANIFOLD INSULATOR |
Remove the 2 bolts and intake manifold insulator.
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| 59. REMOVE INTAKE MANIFOLD |
Detach the sensor wire connector clamp from the intake manifold.
Text in Illustration *1 Sensor Wire
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Disconnect the vacuum hose from the intake manifold.
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Remove the 2 nuts, 4 bolts, intake manifold and gasket.
| 60. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR |
Remove the No. 2 intake manifold insulator.
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| 61. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Loosen the union nuts and remove the fuel inlet pipe.
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| 62. REMOVE COMMON RAIL ASSEMBLY |
Remove the 2 bolts and common rail.
- NOTICE:
- Do not remove the pressure discharge valve or fuel pressure sensor.
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| 63. REMOVE SUPPLY PUMP ASSEMBLY |
Remove the 4 bolts indicated by the arrows in the illustration.
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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.
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Using SST, disconnect the 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.
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Remove the 2 nuts and supply pump.
- NOTICE:
- Do not hold or carry the fuel supply pump by holding the pipe.
- The fuel supply pump must be kept horizontal.
Remove the O-ring.
| 64. REMOVE NO. 1 INJECTION PUMP PROTECTOR |
Remove the 2 bolts and No. 1 injection pump protector.
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| 65. REMOVE OIL FILTER SUB-ASSEMBLY |
Using SST, remove the oil filter.
- SST
- 09228-07501
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| 66. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
Disconnect the vacuum hose.
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Remove the bolt and No. 3 vacuum transmitting pipe.
| 67. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
Disconnect the vacuum hose.
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Remove the 2 nuts and No. 2 vacuum transmitting pipe.
| 68. REMOVE OIL COOLER COVER SUB-ASSEMBLY |
Remove the 13 bolts and oil cooler cover.
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| 69. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
Remove the bolt, nut and No. 1 vacuum transmitting pipe.
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| 70. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 oil pan cover.
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| 71. REMOVE NO. 1 VACUUM PIPE |
Remove the bolt and No. 1 vacuum pipe.
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| 72. REMOVE NO. 2 CYLINDER BLOCK INSULATOR |
Remove the No. 2 cylinder block insulator.
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| 73. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH |
Remove the 8 bolts and 2 engine mounting brackets.
Text in Illustration *A for LH Side *B for RH Side
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