ENGINE ASSEMBLY > REMOVAL

for Preparation Click here

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

1. Disconnect the washer nozzle hose.
   

2. Remove the 4 bolts and hood.
   

1. Remove the 4 bolts and under cover.
   

1. Remove the 2 bolts and under cover.
   

1. Remove the oil filter cap.
   

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

   NOTICE:

   Collect the oil in an oil disposal container.

NOTICE:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

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

2. 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.

   
   
   
   
   
   

1. Stop the vehicle on a level surface.
   

2. Remove the filer plug and gasket.
   

3. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
   If the result is not as specified, add transmission oil.
   

   Oil grade:

   GL-4 or GL-5
   

   Viscosity:

   SAE 75W-90
   

   Capacity:

   2.6 liters (2.7 US qts, 2.3 lmp.qts)
   

   NOTICE:

   1. Too much or too little oil will lead to transmission problems.
      
   2. After adjusting the oil level, drive the vehicle and check the oil level again.
      

4. Check for oil leakage when the oil level is low.
   If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.
   

5. Install a new gasket and the filler plug.
   

   Torque:

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

1. Disconnect the MAF meter connector.
   

2. Loosen the hose clamp.
   

3. Remove the 3 bolts and air cleaner.
   

1. Remove the radiator assembly (Click here).
   

1. Remove the 3 bolts, 2 nuts and engine cover.
   

1. Disconnect the diesel turbo IAT sensor connector.
   

2. Loosen the 2 hose clamps of the No. 1 air hose.
   

3. Loosen the 2 hose clamps of the No. 2 air hose.
   

4. Remove the 4 bolts and CAC.
   

5. Using a 22 mm deep socket wrench, remove the IAT sensor.
   

   HINT:

   Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

6. Remove the 4 bolts, intake air connector and gasket.
   

1. Disconnect the starter connector.
   

2. Remove the nut and disconnect the starter wire.
   

3. A/T:
   Remove the 2 bolts and A/T dipstick.
   

4. M/T:
   Remove the clutch release cylinder.
   

5. A/T:
   Remove the 2 nuts, bolt, ground cable and starter.
   

6. M/T:
   Remove the nut, bolt, ground cable and starter.
   

1. Remove the 2 bolts and 2 compression springs.
   

2. Disconnect the front pipe from the outlet pipe and remove the gasket.
   

3. Remove the front pipe from the pipe support.
   

1. Front Side:
   Remove the propeller shaft assembly (Click here).
   

2. Remove the propeller shaft assembly (Click here).
   

1. Remove the transmission assembly (Click here).
   

1. Remove the transmission assembly (Click here).
   

1. Remove the engine room relay block cover (upper).
   

2. Remove the No. 1 engine room relay block cover (side).
   

3. Remove the nut and disconnect the engine room J/B wire.
   

4. Disconnect the 2 engine room junction block connectors.
   

5. Remove the bolt and disconnect the ground cable.
   

6. Disconnect the 2 injector driver connectors.
   

7. Disconnect the 4WD control ECU connector.
   

8. Disconnect the turbo motor driver connector.
   

9. Disconnect the 3 TCM connectors.
   

10. Disconnect the 4 ECM connectors.
    

11. Disconnect the 2 fuel hoses.
    

12. Disconnect the vacuum pump hose.
    

13. Disconnect the oil reservoir to pump hose.
    

14. Using SST, disconnect the pressure feed tube.
    

    SST

    09023-12701  
    

1. Remove the 4 bolts and disconnect the cooler compressor.
   

   HINT:

   It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

1. Place matchmarks on the clutch cover and flywheel.
   

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

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

   NOTICE:

   Do not drop the clutch disc.

NOTICE:

Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

1. Using SST, hold the crankshaft.
   

   SST

   09213-58013  
   09330-00021  
   

2. Remove the 8 bolts and flywheel.
   

1. Using SST, hold the crankshaft.
   

   SST

   09213-58013  
   09330-00021  
   

2. Remove the 8 bolts, drive plate spacer, drive plate ring gear.
   

1. Remove the bolt and end plate.
   

1. Set the No. 1 engine hanger and No. 2 engine hanger to the locations shown in the illustration.
   

   Torque:

   25 N*m{ 255 kgf*cm , 18 ft.*lbf } for No. 1 engine hanger

   68 N*m{ 693 kgf*cm , 50 ft.*lbf } for No. 2 engine hanger

   Engine Hanger Part No.:

   Parts Name	Parts No.
   Engine hanger No. 1	12284-30020
   	Bolt (91512-61014)
   Engine hanger No. 2	12282-67020
   	Bolt (91642-81030)

   NOTICE:

   Install the engine hangers with new bolts.

2. Hold the engine with the engine sling device and chain block.
   

3. Remove the 4 bolts and 4 nuts.
   

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

1. Disconnect the engine wire from the engine.
   

1. Remove the bolt and water hose clamp.
   

2. Remove the wire harness clamp.
   

3. Remove the 6 bolts and timing belt cover.
   

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

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

3. Remove the timing belt.
   

4. 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.
      
   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, as shown in the illustration.
      

1. Using SST, remove the pulley bolt.
   

   SST

   09213-58013  
   09330-00021  
   

2. Using SST, remove the pulley.
   

   SST

   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 to using it.

1. Remove the bolt of the camshaft timing pulley by holding the camshaft with a wrench.
   

   NOTICE:

   Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

2. Remove the camshaft timing pulley.
   

1. Remove the bolt and insulator.
   

1. Move the 2 clamps and disconnect the 2 hoses.
   

1. Remove the 3 nuts, outlet elbow and gasket.
   

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

   NOTICE:

   Do not loosen the nut labeled A.

1. Remove the 3 bolts and stay.
   

1. Remove the 8 nuts and exhaust manifold w/ turbocharger as shown in the illustration.
   

1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
   

   Maximum warpage:

   0.40 mm (0.0157 in.)
   

   If the warpage is greater than the maximum, replace the manifold.
   

1. Remove the nut and generator wire.
   

2. Disconnect the generator connector.
   

3. Remove the 2 bolts, adjusting bar and generator.
   

1. Remove the 4 bolts and belt tensioner.
   

1. Remove the 2 bolts and support bracket.
   

1. Remove the 2 bolts and support bracket.
   

1. Remove the 4 bolts and mounting bracket.
   

1. Remove the 2 bolts and water outlet.
   

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

1. Remove the 2 bolts and stay.
   

1. Disconnect the 2 connectors.
   

2. Disconnect the vacuum hose from the 3 points shown in the illustration.
   

3. Remove the 2 bolts and bracket.
   

1. Disconnect the 2 connectors.
   

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

1. Remove the 3 bolts and bracket.
   

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

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

1. Remove the EGR valve and gasket.
   

1. Using SST, remove the oil filter.
   

   SST

   09228-07501  
   

   HINT:

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

NOTICE:

1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
   
2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

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

2. Remove the bolt and No. 2 injection pipe clamp.
   

3. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
   

   SST

   09023-12701  
   

   
   
   
   
   

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

   
   
   

   2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.
      

      SST

      09023-12701  
      

1. Disconnect the 2 fuel hoses.
   

2. Remove the check valve, 3 bolts, leakage pipe and gasket.
   

1. Remove the bolt and clamp.
   

2. Remove the 2 bolts and oil level gauge guide.
   

3. Using SST, loosen the union nuts and remove the fuel inlet pipe.
   

   SST

   09023-12701  
   

1. Disconnect the fuel pressure sensor connector.
   

2. Remove the 2 bolts and common rail.
   

   NOTICE:

   Do not remove the pressure limiter and pressure sensor.

1. Remove the bolt and clamp.
   

2. Remove the 2 bolts and oil level gauge guide.
   

3. Using SST, loosen the union nuts and remove the fuel inlet pipe.
   

   SST

   09023-12701  
   

4. Disconnect the 2 fuel hoses.
   

5. Disconnect the 2 connectors.
   

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

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

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

   SST

   09213-58013  
   09330-00021  
   

9. Loosen the 2 nuts.
   

10. 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.

11. Remove the 2 nuts and pump.
    

    NOTICE:

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

12. Remove the O-ring.
    

1. Remove the bolt, oil level gage guide and O-ring.
   

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

1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
   

   Maximum warpage:

   0.40 mm (0.0157 in.)
   

   If the warpage is greater than the maximum, replace the manifold.
   

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

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

1. Remove the bolt, sensor and O-ring.
   

1. Remove the bolt, sensor and O-ring.
   

1. Using a 17 mm deep socket wrench, remove the sensor.
   

1. Remove the 4 bolts and mounting bracket.
   

1. Remove the 4 bolts and mounting bracket.