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 filler 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

1. R151/R151F:
   Drain transmission oil (Click here).

1. G50/G55:
   Drain transmission oil (Click here).

10. REMOVE BATTERY BRACKET

11. REMOVE BATTERY AND BATTERY TRAY

12. REMOVE AIR CLEANER ASSEMBLY

1. Disconnect the IAT sensor 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 STARTER ASSEMBLY

1. Disconnect the starter connector.

1. Remove the nut and disconnect the starter wire.

1. Remove the clutch release cylinder.

1. Remove the nut, bolt, ground cable and starter.

15. 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.

16. REMOVE PROPELLER SHAFT ASSEMBLY

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

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

17. REMOVE TRANSMISSION ASSEMBLY

1. R151/R151F:
   Remove the transmission assembly (Click here).

1. G50/G55:
   Remove the transmission assembly (Click here).

18. 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 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

19. 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.

20. REMOVE CLUTCH COVER ASSEMBLY

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.

21. REMOVE CLUTCH DISC ASSEMBLY

NOTICE:

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

22. REMOVE FLYWHEEL SUB-ASSEMBLY

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

1. Remove the 8 bolts and flywheel.

23. REMOVE REAR END PLATE

1. Remove the bolt and end plate.

24. 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.

25. FIX ENGINE ON ENGINE STAND

26. REMOVE ENGINE WIRE

1. Disconnect the engine wire from the engine.

27. 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.

28. 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.

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

30. REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY

31. 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.

32. 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.

33. REMOVE VENTILATION HOSE HEAT INSULATOR

1. Remove the 2 bolts and insulator.

34. DISCONNECT VENTILATION HOSE

35. REMOVE VENTILATION PIPE

36. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

37. REMOVE EXHAUST MANIFOLD

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

38. 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.

39. REMOVE GENERATOR BRACKET

40. REMOVE GENERATOR ASSEMBLY

1. Remove the nut and generator wire.

1. Disconnect the generator connector.

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

41. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. Remove the 4 bolts and belt tensioner.

42. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

1. Remove the 4 bolts and mounting bracket.

43. REMOVE THERMOSTAT

44. REMOVE WATER OUTLET

1. Remove the 2 bolts and water outlet.

45. REMOVE GLOW PLUG ASSEMBLY

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

46. REMOVE MANIFOLD STAY

1. Remove the 2 bolts and stay.

47. REMOVE DIESEL THROTTLE BODY ASSEMBLY

1. Disconnect the 2 connectors.

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

48. REMOVE DIESEL THROTTLE BODY BRACKET

1. Remove the 3 bolts and bracket.

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

49. REMOVE INTAKE AIR CONNECTOR

1. Remove the 2 bolts, air connector and bracket.

50. 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.

51. 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

52. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

1. Disconnect the 2 fuel hoses.

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

53. 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

54. 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.

55. 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.

56. REMOVE OIL LEVEL GAUGE GUIDE

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

57. REMOVE INTAKE MANIFOLD

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

58. 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.

59. REMOVE OIL COOLER COVER SUB-ASSEMBLY

1. Disconnect the oil pressure switch connector and wire harness.

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

60. REMOVE VACUUM PUMP ASSEMBLY

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

61. REMOVE VANE PUMP ASSEMBLY

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

62. REMOVE CRANKSHAFT POSITION SENSOR

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

63. REMOVE CAMSHAFT POSITION SENSOR

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

64. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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

65. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH

1. Remove the 4 bolts and mounting bracket.

66. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

1. Remove the 4 bolts and mounting bracket.