Engine Assembly Removal

Disconnect the washer nozzle hose.

Remove the 4 bolts and hood.

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

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

Remove the oil filler cap.

Remove the oil drain plug, and drain the engine oil from the oil pan.

NOTICE:

Collect the oil in an oil disposal container.

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

Loosen the cylinder block drain cock plug and the radiator drain cock plug.

HINT:

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

Remove the bolt, nut and battery clamp.

Disconnect the MAF meter connector.

Loosen the hose clamp.

Remove the 2 bolts and air cleaner.

Remove the 3 bolts, 2 nuts and engine cover.

Disconnect the IAT sensor connector.

Disconnect the manifold absolute diesel pressure sensor connector.

Disconnect the vacuum hose from the manifold absolute pressure sensor.

Loosen the 2 clamps.

Remove the 4 bolts and CAC.

Place matchmarks on the yoke and differential flange.

Remove the 4 nuts, 4 bolts and 4 washers, and disconnect the propeller shaft.

Place matchmarks on the yoke and transfer flange.

Remove the 4 nuts, 4 washers and front propeller shaft.

While pushing in the sides of the glove compartment door to release the 2 stoppers, 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.

Disconnect the 3 EDU connectors.

Disconnect the turbo motor driver connector.

Disconnect the 3 TCM connectors.

Disconnect the 4 ECM connectors.

Disconnect the 2 fuel hoses.

Disconnect the vacuum pump hose.

Disconnect the oil reservoir to pump hose.

Using a union nut wrench, disconnect the pressure feed tube.

Disconnect the 2 heater hoses.

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.

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.

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

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

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.

HINT:

Part No.

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.

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.

Remove the engine wire from the engine.

Remove the bolt and water hose clamp.

Remove the wire harness clamp.

Remove the 6 bolts and timing belt cover.

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

Uniformly loosen the 2 bolts and remove the timing belt tensioner.

Remove the timing belt.

Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

HINT:

1. 
   
2. When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
3. When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks.
   

Using SST, remove the pulley bolt.

SST

09213-58014
09330-00021

Using SST, remove the pulley.

SST

09213-58014
09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

NOTICE:

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

Remove the bolt from the ventilation pipe.

Move the clamp so that the hose can be disconnected.

Disconnect the ventilation pipe from the cylinder head cover.

Disconnect the 2 connectors from the turbocharger.

Remove the harness clamp's clip from the inlet elbow.

Remove the 2 nuts, inlet elbow and gasket.

Remove the bolt and insulator.

Remove the bolt and insulator.

Move the 2 clamps and disconnect the 2 hoses.

Remove the 3 nuts, outlet elbow and gasket.

Remove the 3 bolts and stay.

Remove the 2 bolts, 2 nuts, union bolt, inlet pipe and 3 gaskets.

NOTICE:

Do not loosen the nut labeled A.

Remove the 8 nuts, 8 collars, 8 spacers and exhaust manifold with turbocharger as shown in the illustration.

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

Disconnect the terminal cap.

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 2 bolts and No. 1 intercooler support bracket.

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

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

for Automatic transmission:
Remove the bolt and disconnect the clamp.

Remove the 3 bolts and inlet.

Remove the 2 bolts, water outlet and gasket.

Remove the nut and wire harness.

Remove the 4 screw grommets, 4 nuts and glow plug connector.

Using a 12 mm deep socket wrench, remove the 4 glow plugs.

Remove the 2 bolts and manifold stay.

Disconnect the throttle position sensor connector.

Disconnect the throttle control motor connector.

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

Disconnect the 2 connectors.

Disconnect the vacuum hoses from the 3 locations.

Remove the 2 bolts and bracket.

Remove the 3 bolts and No. 2 intake air connector bracket.

Remove the 2 nuts, bolt, air connector and gasket.

Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.

Remove the EGR valve and gasket.

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.

Remove the bolt and No. 2 injection pipe clamp.

Remove the 2 nuts and No. 3 injection pipe clamp.

Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

Remove the 2 bolts and disconnect the 2 injection pipe clamps.

NOTICE:

If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

Disconnect the 3 fuel hoses.

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

Remove the engine oil level dipstick.

Remove the bolt and clamp.

Remove the bolt and engine oil level dipstick guide.

Remove the O-ring engine oil level dipstick guide.

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

Disconnect the 2 connectors.

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

NOTICE:

Do not remove the pressure discharge valve and fuel pressure sensor.

Remove the bolt and clamp.

Remove the bolt and oil dipstick guide.

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

Disconnect the 2 fuel hoses.

Disconnect the 2 connectors.

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

09213-58013
09330-00021

Loosen the 2 nuts.

Using SST, disconnect the 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 pump.

NOTICE:

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

Remove the O-ring.

Remove the bolt, engine oil level dipstick guide and O-ring.

Remove the 4 bolts, 2 nuts, intake manifold and gasket.

Disconnect the oil pressure switch connector and wire harness.

Remove the 13 bolts, 2 nuts and oil cooler cover.

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

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

Remove the bolt and crankshaft position sensor.

Remove the bolt and camshaft position sensor.

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

Remove the 2 nuts and 2 front engine mounting insulators.

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

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