GSIC - Global Service Information Center

# ENGINE ASSEMBLY > REMOVAL

## for Preparation Click here

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

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

2. REMOVE HOOD SUB-ASSEMBLY

1. Disconnect the washer nozzle hose.

1. Remove the 4 bolts and hood.

3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

1. Remove the 4 bolts and under cover.

4. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)

1. Remove the 2 bolts and under cover.

5. DRAIN ENGINE OIL

1. Remove the oil filter cap.

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

   NOTICE:
     Collect the oil in an oil disposal container.

6. LOOSEN FUEL TANK CAP ASSEMBLY

7. DRAIN FUEL

8. DRAIN ENGINE COOLANT

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.

1. 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.

9. DRAIN TRANSMISSION OIL (for Manual Transmission)

1. Stop the vehicle on a level surface.

1. Remove the filer plug and gasket.

1. 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.

1. 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.

1. Install a new gasket and the filler plug.

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

10. REMOVE BATTERY BRACKET

11. REMOVE BATTERY AND BATTERY TRAY

12. REMOVE AIR CLEANER ASSEMBLY

1. Disconnect the MAF meter connector.

1. Loosen the hose clamp.

1. Remove the 3 bolts and air cleaner.

13. REMOVE RADIATOR ASSEMBLY

1. Remove the radiator assembly (Click here).

14. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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

15. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

1. Disconnect the diesel turbo IAT sensor connector.

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

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

1. Remove the 4 bolts and CAC.

1. 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.

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

16. REMOVE STARTER ASSEMBLY

1. Disconnect the starter connector.

1. Remove the nut and disconnect the starter wire.

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

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

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

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

17. REMOVE FRONT EXHAUST PIPE ASSEMBLY

1. Remove the 2 bolts and 2 compression springs.

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

1. Remove the front pipe from the pipe support.

18. REMOVE PROPELLER SHAFT ASSEMBLY

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

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

19. REMOVE TRANSMISSION ASSEMBLY (for Manual Transmission)

1. Remove the transmission assembly (Click here).

20. REMOVE TRANSMISSION ASSEMBLY (for Automatic Transmission)

1. Remove the transmission assembly (Click here).

21. DISCONNECT HOSES AND CONNECTORS

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

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

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

1. Disconnect the 2 engine room junction block connectors.

1. Remove the bolt and disconnect the ground cable.

1. Disconnect the 2 injector driver connectors.

1. Disconnect the 4WD control ECU connector.

1. Disconnect the turbo motor driver connector.

1. Disconnect the 3 TCM connectors.

1. Disconnect the 4 ECM connectors.

1. Disconnect the 2 fuel hoses.

1. Disconnect the vacuum pump hose.

1. Disconnect the oil reservoir to pump hose.

1. Using SST, disconnect the pressure feed tube.

   SST
     09023-12701

22. DISCONNECT COOLER COMPRESSOR ASSEMBLY

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.

23. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

1. Place matchmarks on the clutch cover and flywheel.

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

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

   NOTICE:
     Do not drop the clutch disc.

24. REMOVE CLUTCH DISK ASSEMBLY (for Manual Transmission)

NOTICE:

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

25. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

1. Remove the 8 bolts and flywheel.

26. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

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

27. REMOVE REAR END PLATE

1. Remove the bolt and end plate.

28. REMOVE ENGINE ASSEMBLY

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.

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

1. Remove the 4 bolts and 4 nuts.

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

29. FIX ENGINE ON ENGINE STAND

30. REMOVE ENGINE WIRE

1. Disconnect the engine wire from the engine.

31. REMOVE NO. 1 TIMING BELT COVER

1. Remove the bolt and water hose clamp.

1. Remove the wire harness clamp.

1. Remove the 6 bolts and timing belt cover.

32. REMOVE TIMING BELT

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

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

1. Remove the timing belt.

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

   HINT:
   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.

33. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

34. REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY

35. REMOVE CRANKSHAFT PULLEY

1. Using SST, remove the pulley bolt.

   SST
     09213-58013
     09330-00021

1. 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.

36. REMOVE CAMSHAFT TIMING PULLEY

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.

1. Remove the camshaft timing pulley.

37. DISCONNECT VENTILATION HOSE

38. REMOVE VENTILATION PIPE

39. REMOVE NO. 1 TURBO INSULATOR

1. Remove the bolt and insulator.

40. REMOVE NO. 1 TURBO WATER HOSE

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

41. REMOVE TURBINE OUTLET ELBOW

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

42. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

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

   NOTICE:
     Do not loosen the nut labeled A.

43. REMOVE TURBOCHARGER STAY

1. Remove the 3 bolts and stay.

44. REMOVE EXHAUST MANIFOLD

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

45. INSPECT EXHAUST MANIFOLD

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.

46. REMOVE GENERATOR BRACKET

47. REMOVE GENERATOR ASSEMBLY

1. Remove the nut and generator wire.

1. Disconnect the generator connector.

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

48. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. Remove the 4 bolts and belt tensioner.

49. REMOVE NO. 1 CHARGE AIR COOLER SUPPORT BRACKET

1. Remove the 2 bolts and support bracket.

50. REMOVE NO. 2 CHARGE AIR COOLER SUPPORT BRACKET

1. Remove the 2 bolts and support bracket.

51. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

1. Remove the 4 bolts and mounting bracket.

52. REMOVE THERMOSTAT

53. REMOVE WATER OUTLET

1. Remove the 2 bolts and water outlet.

54. REMOVE GLOW PLUG ASSEMBLY

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

55. REMOVE MANIFOLD STAY

1. Remove the 2 bolts and stay.

56. REMOVE VACUUM SWITCHING VALVE BRACKET

1. Disconnect the 2 connectors.

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

1. Remove the 2 bolts and bracket.

57. REMOVE DIESEL THROTTLE BODY ASSEMBLY

1. Disconnect the 2 connectors.

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

58. REMOVE DIESEL THROTTLE BODY BRACKET

1. Remove the 3 bolts and bracket.

59. REMOVE INTAKE AIR CONNECTOR

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

60. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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

61. REMOVE EGR VALVE ASSEMBLY

1. Remove the EGR valve and gasket.

62. REMOVE OIL FILTER SUB-ASSEMBLY

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.

63. REMOVE INJECTION PIPE

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.

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

1. 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

64. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

1. Disconnect the 2 fuel hoses.

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

65. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

1. Remove the bolt and clamp.

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

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

   SST
     09023-12701

66. REMOVE COMMON RAIL ASSEMBLY

1. Disconnect the fuel pressure sensor connector.

1. Remove the 2 bolts and common rail.

   NOTICE:
     Do not remove the pressure limiter and pressure sensor.

67. REMOVE FUEL SUPPLY PUMP ASSEMBLY

1. Remove the bolt and clamp.

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

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

   SST
     09023-12701

1. Disconnect the 2 fuel hoses.

1. Disconnect the 2 connectors.

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

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

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

   SST
     09213-58013
     09330-00021

1. Loosen the 2 nuts.

1. 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.

1. 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.

1. Remove the O-ring.

68. REMOVE OIL LEVEL GAUGE GUIDE

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

69. REMOVE INTAKE MANIFOLD

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

70. INSPECT INTAKE MANIFOLD

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.

71. REMOVE OIL COOLER COVER SUB-ASSEMBLY

72. REMOVE VACUUM PUMP ASSEMBLY

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

73. REMOVE VANE PUMP ASSEMBLY

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

74. REMOVE CRANKSHAFT POSITION SENSOR

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

75. REMOVE CAMSHAFT POSITION SENSOR

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

76. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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

77. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH

1. Remove the 4 bolts and mounting bracket.

78. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

1. Remove the 4 bolts and mounting bracket.