Engine Assembly Removal

Remove the 11 clips and intake duct seal.

Remove the 4 clips and side cover.

Remove the 2 clips and side cover.

Remove the No. 1 engine cover.

Start up the engine.

Turn the A/C switch on.

Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

Stop the engine.

Using SST, let the refrigerant gas out.

SST

07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

Remove the 4 bolts and suspension member protector.

Remove the 2 bolts and engine under cover air guide bracket.

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

Remove the radiator cap.

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

HINT:

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

Remove the bolt, clip and inlet air cleaner.

Disconnect the MAF meter connector.

Disconnect the 2 clamps from the air cleaner.

Disconnect the ventilation hose from the cylinder head.

Disconnect the 4 clamps.

Remove the hose clamp and air cleaner cap with air cleaner hose.

Remove the 3 bolts, clamp and air cleaner case.

Remove the clip, clamp, and air duct.

Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.

Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water outlet hose.

Using pliers, grip the claws of the clip and slide the clip to disconnect the fuel hose.

Disconnect the connector.

Remove the 4 bolts and heater assembly.

Remove the clamp and disconnect the union to the check valve hose.

Disconnect the wiring harness clamp.

Disconnect the 6 wire harness clamps (^*1).

Disconnect the EGR valve connector (^*2).

Disconnect the oil pressure switch assembly connector (^*3).

Remove the 2 bolts and wire harness clamp bracket.

Remove the 2 nuts, 2 bolts and No. 2 EGR pipe.

Disconnect the manifold absolute pressure sensor connector and vacuum hose.

Remove the insulator.

Disconnect the 2 water hoses.

Remove the 3 bolts and No. 1 water outlet pipe.

Disconnect the 2 diesel throttle body connectors.

Loosen the 3 hose bands.

Disconnect the intake air temperature sensor connector.

Remove the bolt and air pipe sub-assembly.

Disconnect the wire harness clamp.

Remove the clamp and disconnect the vacuum transmitting hose.

Remove the clamp and disconnect the reserve tank outlet hose.

Disconnect the radiator outlet hose.

Disconnect the heater water inlet hose.

Disconnect the heater water outlet hose.

Remove the clamp and disconnect the No. 1 air hose.

Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.

Remove the O-ring from the cooler refrigerant suction hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

Remove the bolt and disconnect the discharge hose from the compressor.

Remove the O-ring from the discharge hose sub-assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

Disconnect the differential pressure sensor connector and remove the nut.

Disconnect the No. 1 vacuum transmitting hose and No. 2 vacuum transmitting hose.

Remove the differential pressure sensor.

Remove the relay block cover.

Disconnect the engine wire from the engine room junction block.

Raise the 2 levers while pushing the locks on the 2 levers, and disconnect the 2 ECM connectors.

NOTICE:

After disconnecting the connector, make sure that dirt, water and other foreign matter does not contact the connecting part of the connector.

Remove the 2 nuts and disconnect the wire clamps from the engine room No. 1 junction block.

Remove the bolt, clamp and engine wire No. 3.

Disconnect 3 injector connectors and the 2 wire harness clamps.

Remove the clamp and disconnect the fuel hose.

Remove the clamp and disconnect the No. 3 fuel hose.

Fix the steering wheel with the seat belt in order to prevent rotation.

HINT:

This operation is useful to prevent damage to the spiral cable.

Loosen bolt (A) and remove bolt (B), then slide the steering sliding yoke sub-assembly.

NOTICE:

1. Do not remove bolt (A).
   
2. Do not separate the steering sliding yoke sub-assembly from the power steering gear assembly.
   

Put matchmarks on the steering sliding yoke sub-assembly and the power steering gear assembly.

Separate the steering sliding yoke sub-assembly from the power steering gear assembly.

Remove the nut and disconnect the height control sensor link.

Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

Remove the 2 bolts from the front lower ball joint.

Remove the bolt (A) to disconnect the earth wire from the bracket.

Remove the 2 clamps to disconnect the wire harness from the bracket.

Disconnect the 2 connectors (C) and (D) from the power steering link assembly.

Release the lock of connector (E) and disconnect the connector from the power steering link assembly.

Remove the bolt (B) and the power steering earth wire from the power steering link assembly.

Set the engine lifter.

Remove the 4 bolts, then separate the engine rear mounting member.

Remove the 12 bolts shown in the illustration.

Operate the engine lifter, then slowly remove the engine from the vehicle.

NOTICE:

Make sure that the engine does not get caught on wiring or hoses when removing it.

Install the 2 engine hangers with the 2 bolts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

NOTICE:

Use new bolts for the engine hangers.

Disconnect the 2 wire harness clamps from the wire harness clamp bracket.

Remove the bolt and wire harness clamp bracket.

Disconnect the terminal 50 connector from the starter assembly.

Remove the nut and disconnect the wire harness from terminal 30.

Remove the bolt, nut and starter assembly.

Hold the crankshaft with SST.

SST

09213-58013
09330-00021

Remove the 8 bolts and the flywheel.

Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

Fix the engine onto a engine stand with the bolts.

Remove the engine wire from the engine assembly.

Release the belt tension by turning the belt tensioner counterclockwise, and remove the V-ribbed belt from the belt tensioner.

While turning the belt tensioner counterclockwise, align its holes, and then insert a 5 mm (0.20 in.) bar into the holes to hold the belt tensioner.

Pinch the clip as illustrated, and then pull out the vacuum switching valve connector (^*1).

Disconnect the 2 vacuum hoses (^*2).

Using a hexagon socket wrench, remove the 2 bolts and No. 1 vacuum switching valve assembly (^*3).

Disconnect the 2 vacuum hoses.

Disconnect the vacuum regulating valve assembly connector.

Remove the 2 bolts, and then remove the vacuum regulating valve assembly.

Remove the 4 bolts and vacuum switching valve bracket.

Disconnect the generator connector.

Remove the bolt and disconnect the wire harness clamp bracket.

Remove the nut and disconnect the wire harness from terminal B.

Disconnect the clamp from the clamp bracket.

Remove the 3 bolts (A) and generator assembly.

Remove the bolt (B) and clamp bracket from the generator assembly.

Remove the 2 bolts, 2 nuts and idler pulley bracket.

Using a screwdriver, remove the idler pulley cover plate.

Remove the bolt and idler pulley sub-assembly.

Remove the 3 bolts and tensioner assembly.

NOTICE:

Be careful not to deform the bolt head.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Using a "Torx" socket wrench (E8), remove the stud bolt and the compressor assembly with pulley.

Remove the No. 1 compressor stay from the engine block.

Remove the 2 bolts and exhaust manifold heat insulator.

Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

Using a precision straightedge and feeler gauge, measure for any warpage on its cylinder head contact surface.

Maximum warpage:

0.2 mm (0.0079 in.)

Remove the 2 bolts, EGR valve assembly and gasket.

Disconnect the fuel pressure sensor connector (^*1).

Disconnect the fuel hose.

Disconnect the pressure discharge valve connector (^*2).

Remove the 2 bolts and the common rail assembly.

Remove the 5 grommets.

Remove the 5 nuts and the glow plug connector.

Remove the 4 glow plugs.

Remove the 3 bolts and oil level gauge.

Remove the O-ring from the oil level gauge.

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

Remove the 2 bolts and intake manifold stay.

Remove the 7 bolts and 2 nuts, and then remove the intake manifold and the gasket.

Using a precision straightedge and feeler gauge, measure for any warpage on its cylinder head contact surface.

Maximum warpage:

0.1 mm (0.0039 in.)

Disconnect the oil cooler hose.

Remove the 5 bolts, 3 O-rings and oil cooler assembly.

Remove the engine coolant temperature sensor.

Remove the 2 bolts, O-ring and No. 3 water by-pass pipe.

Remove the 2 union bolts, 2 gaskets and oil pipe.

Remove the 6 bolts and nut, and then remove the oil cooler bracket and the 3 O-rings.

Remove the 2 bolts, O-ring and No. 2 water by-pass pipe.

Disconnect the hose.

Remove the 3 nuts, gasket and water inlet housing.

Remove the 4 bolts, then remove the oil level sensor and gasket.