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1. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    A00K0NWE01

  1. Remove the 4 bolts and compressor mounting bracket.



2. REMOVE CRANKSHAFT PULLEY


A00JYNOE02

  1. Using SST, remove the pulley bolt.

    SST
    09213-54015   (91651-60855)
    09330-00021  
    Text in Illustration 
    *a
    		Hold
    *b
    		Turn



    A00JVDXE02

  1. Using SST, remove the pulley.

    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05021)
    09950-60010   (09951-00490)
    09950-40011   (09957-04010)
    Text in Illustration 
    *a
    		Hold
    *b
    		Turn



3. REMOVE TIMING BELT COVER


    A00JXCM

  1. Remove the 11 bolts, washers, timing belt cover, and 2 gaskets.



4. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    A00K232E03

  1. Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.
    Text in Illustration 
    *1
    		Timing Mark
    A00JWY4
    		Turn



    A00JY76E02

  1. Check that the timing marks of the camshaft timing pulley and No. 2 timing belt cover are aligned.
    Text in Illustration 
    *1
    		Timing Mark
    If not, turn the crankshaft 1 revolution (360°).



5. REMOVE TIMING BELT

УКАЗАНИЕ:
If reusing the timing belt, draw a direction arrow on the timing belt (in the direction the belt move when the engine is running), and place matchmarks on the pulleys and timing belt.



    A00JV64

  1. Turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.
    Text in Illustration 
    A00JWY4
    		Turn

    ПРИМЕЧАНИЕ:
    If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley, and camshaft causing damage. Therefore, always set the crankshaft pulley is removed at the correct angle.



    A00JZURE02

  1. Loosen the No. 1 timing belt idler bolt (A), and shift the idler to the left as far as possible.
    Text in Illustration 
    A00JWY4
    		Pry
    A00JYOS
    		Move

  1. Tighten the No. 1 timing belt idler bolt (A), and then relieve the timing belt tension.

  1. Remove the timing belt.



6. REMOVE CRANKSHAFT TIMING PULLEY


    A00JZ4VE02

  1. Using a screwdriver, remove the crankshaft timing pulley.

    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

    УКАЗАНИЕ:
    If the timing pulley cannot be removed by using a screwdriver, remove it with SST.



7. REMOVE INTAKE FLANGE


    A009747

  1. Remove the bolt and disconnect the PCV hose and heater hose bracket.



    A009A45

  1. Disconnect the manifold absolute pressure sensor connector.



    A0095KM

  1. Remove the 3 nuts, intake flange and gasket.



8. REMOVE DIESEL THROTTLE BODY


    A00979C

  1. Disconnect the throttle open switch connector.

  1. Remove the 2 bolts and disconnect the wire harness bracket.



    A00947WE02

  1. Disconnect the throttle control motor connector.

  1. Remove the diesel throttle body and gasket.



9. REMOVE INJECTION PIPE SET


    A00JY0JE03

  1. Using a union nut wrench, loosen the 8 union nuts of the 4 injection pipes.
    Text in Illustration 
    *1
    		Union Nut Wrench
    *a
    		for Injection Nozzle Side
    *b
    		for Injection Pump Side

  1. Remove the 2 nuts, 2 upper pipe clamps and 4 injection pipes with 2 lower pipe clamps.



10. REMOVE NO. 1 GLOW PLUG CONNECTOR


    A00JTSS

  1. Remove the nut, No. 2 glow plug resistor insulator and washer and disconnect the wire harness.

  1. Remove the 4 screw grommets and 4 nuts.

  1. Remove the No. 1 glow plug connector and No. 1 glow plug resistor insulator.



11. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    A00JV8C

  1. Disconnect the fuel hose from the leakage pipe.

  1. Remove the 4 nuts, leakage pipe and 4 ring packing washers.



12. REMOVE NOZZLE HOLDER & NOZZLE SET


    A00JX41E01

  1. Using SST, remove the 4 injection nozzles, 4 injection nozzle seats and 4 injection nozzle seat gaskets.

    SST
    09268-64010   (09268-64020)



13. REMOVE GLOW PLUG ASSEMBLY


    A00K050

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



14. REMOVE INJECTION PUMP DRIVE PULLEY


    A00K1PUE01

  1. Using SST, remove the pulley nut.

    SST
    09213-14010   (91651-60865)
    09330-00021  



    A00JTPFE01

  1. Using SST, remove the drive pulley.

    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05010, 09954-05021)



15. REMOVE INJECTION PUMP ASSEMBLY


    A00JTZI

  1. Disconnect the 5 connectors and detach the wire harness clamp.

  1. Disconnect the 3 fuel hoses.



    A00JX2I

  1. Remove the 3 bolts and injection pump stay.

  1. Remove the 2 nuts and injection pump.



16. REMOVE CRANK POSITION SENSOR


    A009B0Z

  1. Disconnect the crankshaft position sensor connector.

  1. Remove the bolt and crankshaft position sensor.



17. REMOVE WATER OUTLET HOUSING


    A00JZLG

  1. Remove the 3 bolts, outlet housing and gasket.



18. REMOVE INTAKE MANIFOLD


    A00JYIM

  1. Remove the 6 bolts, 2 nuts, intake manifold and gasket.



19. REMOVE WATER BY-PASS HOSE UNION

  1. Remove the water by-pass hose union.



20. REMOVE NO. 1 GENERATOR BRACKET


    A00JUX7

  1. Remove the 3 bolts and No. 1 generator bracket.



21. REMOVE PUMP BRACKET


    A00JVPH

  1. Remove the 3 bolts and pump bracket.



22. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Remove the dipstick.



    A00JWDK

  1. Remove the 2 bolts and dipstick guide.

  1. Remove the O-ring from the dipstick guide.



23. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    A00JU60

  1. Remove the 4 bolts and engine mounting bracket.



24. REMOVE VACUUM PUMP OIL INLET HOSE


    A00JWVQ

  1. Remove the union bolt and gasket, and then disconnect the vacuum pump oil inlet hose from the cylinder block.



25. REMOVE UNION


    A00JUTC

  1. Remove the union from the cylinder block.



26. REMOVE VACUUM PUMP OIL OUTLET HOSE


    A00JUT4

  1. Remove the bolt, 2 gaskets and vacuum pump outlet hose.



27. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    A00JYS8

  1. Remove the 4 bolts and engine mounting bracket.



28. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    A0096YM

  1. Remove the 3 bolts and insulator.



29. REMOVE EXHAUST MANIFOLD


    A009BTK

  1. Remove the 2 nuts, 6 bolts and manifold.

  1. Remove the gasket.



30. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    A00JUOB

  1. Remove the 10 bolts, 2 nuts, oil filter bracket and gasket.



31. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    A009AG5

  1. Using a 24 mm deep socket wrench, remove the oil pressure switch.