Removal Procedure
- Engine - Remove - Engine Removal and Installation (4WD, with RC1, without F47) , or Engine Removal and Installation (2WD, with RC1, without F47) , or Engine Removal and Installation (4WD, with RC1, with F47) , or Engine Removal and Installation (2WD, with RC1, with F47) , or Engine Removal and Installation (4WD, with WTX, with F47) , or Engine Removal and Installation (2WD, with WTX, with F47) , or Engine Removal and Installation (4WD, with WTX, without F47) , or Engine Removal and Installation (2WD, with WTX, without F47)
- Remove the EN-52474 Engine Lift Hook Set
Place a drain pan underneath the oil pan.
- Oil Pan Drain Plug (1) - Remove
- Oil Pan Drain Plug Seal (2) - Remove
- Oil Filter (3) - Remove and DISCARD
Turbocharger Bracket Bolt (1) - Remove
- Turbocharger Bracket Nut (2) - Remove [2x]
- Turbocharger Bracket Brace (3) - Remove
Charge Air Cooler Bolt (3) - Remove [5x]
- Charge Air Cooler Bracket (4) - Remove
Thermostat Bypass Pipe Bolt (2) - Remove
- Thermostat Bypass Hose Clamp (3) - Release - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (1) - Remove
Thermostat Bypass Pipe Bolt (3) - Remove [2x]
- Thermostat Bypass Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) - Remove
- Engine Coolant Thermostat Gasket (4) - Remove and DISCARD
Clip (3) @ Exhaust Gas Recirculation Cooler Outlet Pipe - Disengage
- Engine Coolant Air Bleed Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Pipe (2) - Remove
Remove the fuel injector wiring harness connector (1) from the engine coolant air bleed hose.
- Remove the wiring harness clip (2) from the engine coolant air bleed hose.
Engine Coolant Air Bleed Hose Stud (2) - Remove
- Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]
Turbocharger Coolant Feed and Return Pipe Gasket (1) - Remove and DISCARD [2x]
Engine Coolant Outlet Pipe Bracket Bolt (2) - Remove
Turbocharger Coolant Feed and Return Pipe Gasket (1) - Remove and DISCARD
- Engine Coolant Air Bleed Hose (1) - Remove
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NOTE:Support the exhaust gas recirculation cooler inlet and outlet pipes when applying torque to the bolts.
Exhaust Gas Recirculation Cooler Bolt (1) @ Exhaust Gas Recirculation Cooler Inlet Pipe - Remove [2x]
- Exhaust Gas Recirculation Cooler Bolt (2) - Remove
- Exhaust Gas Recirculation Outlet Pipe Bolt (3) @ Fuel Injection Fuel Feed Pipe Bracket - Remove
- Exhaust Gas Recirculation Cooler Outlet Pipe Bolt (4) @ Intake Manifold - Remove [2x]
- Exhaust Gas Recirculation Cooler Outlet Pipe (5) - Remove
- Exhaust Gas Recirculation Pipe Seal (6) - Remove and DISCARD
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (7) - Remove and DISCARD
- NOTE:
Support the exhaust gas recirculation cooler inlet pipe when applying torque to the bolts.
NOTE:Considering the reduced clearance, carefully remove the bolts to ensure the tool does not contact the pipe.
Exhaust Gas Recirculation Cooler Bolt (1) - Remove [2x]
- Exhaust Gas Recirculation Cooler Inlet Pipe (2) - Remove
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Remove and DISCARD
Oil Level Indicator (2) - Remove
- Oil Level Indicator Tube Bolt (3) - Remove [2x]
- Clip (4) @ Oil Level Indicator Tube - Remove
Oil Level Indicator Tube (1) - Remove
- Oil Level Indicator Seal (2) - Remove and DISCARD
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Camshaft Housing Cover Insulator (1) - Remove
Positive Crankcase Ventilation Hose Clamp (1) - Release [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Positive Crankcase Ventilation Hose (2) - Remove
Exhaust Gas Recirculation Valve Cooling Feed Hose Clamp (1) - Release - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Valve Cooling Feed Hose (2) - Remove
Exhaust Gas Recirculation Valve Bolt (1) - Remove [2x]
- Exhaust Gas Recirculation Valve (2) - Remove
- Exhaust Gas Recirculation Valve Inlet Gasket (3) - Remove and DISCARD
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Turbocharger Oil Feed Pipe Bolt (7) - Remove [2x]
- Turbocharger Oil Feed Pipe Bracket Bolt (9) Remove
- Turbocharger Oil Return Pipe Bolt (8) - Remove [2x]
- Turbocharger Nut (2, 4) - Remove and DISCARD [3x]
- Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (3) - Remove and DISCARD
- Turbocharger Oil Feed Pipe Gasket (6) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Exhaust Manifold Heat Shield Bolt (1) - Remove [2x]
- Exhaust Manifold Heat Shield - Remove
Exhaust Manifold Flange Bolt (1) - Remove [12x]
- Exhaust Manifold (2) - Remove
- Exhaust Manifold Gasket (3) - Remove and DISCARD
Diesel Glow Plug Wiring Harness (1) @ Intake Manifold - Remove
Intake Manifold Cover Retainer (2) - Remove [2x]
- Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (2) - Remove [9x]
- Intake Manifold (1) - Remove
- Intake Manifold Runner Control Valve Gasket (3) - Remove and DISCARD [6x]
Engine Oil Cooler Bolt (1) - Remove [5x]
Engine Oil Cooler (1) - Remove
- Engine Oil Cooler Gasket (2) - Remove and DISCARD
- Engine Oil Cooler Seal (3) - Remove and DISCARD
Engine Coolant Flow Control Valve Bolt (3) - Remove [6x]
- Engine Coolant Flow Control Valve (2) - Remove
- Engine Coolant Thermostat Housing Gasket (1) - Remove and DISCARD
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3)
- Crankshaft Pulley Bolt (2) - Loosen [4x]
Automatic Transmission Flex Plate Bolt (2) - Remove and DISCARD [8x]
- Automatic Transmission Flex Plate (1) - Remove
Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
Crankshaft Pulley Bolt (2) - Remove [4x]
- Crankshaft Pulley (1) - Remove
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Water Pump Bolt (6) - Remove [2x]
- Water Pump Inlet Pipe (1) - Remove
- Radiator Outlet Pipe Seal (2) - Remove and DISCARD
- Water Pump Bolt (5) - Remove [4x]
- Water Pump (4) - Remove
- Water Pump Gasket (3) - Remove and DISCARD
Engine Front Cover Bolt (1) - Remove [8x]
- Using EN-37228 separating tool, loosen the crankshaft front oil seal carefully from the engine block.
- Crankshaft Front Oil Seal (2) - Remove and DISCARD
Crankshaft Pulley Bolt (1) - Install and hand tighten [4x]
- Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the following alignment is achieved:
- The crankshaft locking divot (2) aligns with the engine block (3)
- The crankshaft timing mark, dimension a, is at 40 degrees TDC
- Install the EN-52586 Crankshaft Fixing Pin (4).
Wiring Harness Connector (1) @ Fuel Injector Wiring Harness - Disconnect [6x]
- Retaining Clip (2) @ Fuel Injector Wiring Harness - Remove [8x]
- Fuel Injector Wiring Harness (3) - Remove
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Push the 6 fuel injection fuel return pipe locking springs (1) in the direction shown and remove the fuel injection fuel return pipe from the fuel injectors.
- Fuel Injection Fuel Return Pipe Clip (4) @ High Pressure Diesel Fuel Injection Rail - Remove
- Unlock the fuel injection fuel return pipe clip (5) by pressing the spring notch in direction of the arrow, and remove the hose from the diesel fuel separator.
- Unclip the fuel injection fuel pipe retainer (3) from the high pressure fuel feed pipe.
- Fuel Injection Fuel Return Pipe (2) - Remove
- Seal Ring (6) - Remove and DISCARD [6x]
Heater Outlet Pipe Bolt (1) @ Fuel Pump Fuel Feed Hose - Remove
- Fuel Feed Hose Connector Retainer (3) - Disengage
- Disconnect the fuel pump fuel feed hose (4). Metal Collar Quick Connect Fitting Service
- Fuel Pump Fuel Feed Hose (2) - Remove
Heater Outlet Pipe Bolt (1) @ Diesel Fuel Separator - Remove
- Fuel Return Hose Connector Retainer (4) - Disengage
- Disconnect the fuel return front pipe (3). Metal Collar Quick Connect Fitting Service
- Diesel Fuel Separator (2) - Remove
High Pressure Diesel Fuel Feed to Rail Pipe (1) @ High Pressure Diesel Fuel Injection Rail (5) - Disconnect [2x]
- High Pressure Diesel Fuel Feed to Rail Pipe (1) @ High Pressure Diesel Fuel Pump (4) - Disconnect [2x]
- Fuel Feed Pipe Clip Bolt (2, 3) - Remove [4x]
- High Pressure Diesel Fuel Feed to Rail Pipe (1) - Remove and DISCARD [2x]
Fuel Return Pipe Clip Bolt (1) - Remove [2x]
- Fuel Injector Fuel Return Hose Bracket (2) - Remove
Fuel Injection Fuel Feed and Return Pipe Retainer Bolt (2) - Remove
- Fuel Injection Fuel Feed Pipe Bracket (1) - Remove
High Pressure Diesel Fuel Feed to Injector Pipe (1) - Remove and DISCARD [6x]
Clip (1) @ Diesel Glow Plug Wiring Harness - Unclip [3x]
- Electrical Connector (2) @ Glow Plug - Disconnect [6x]
- Diesel Glow Plug Wiring Harness (3) - Remove
Fuel Injection Fuel Rail Nut (3) - Remove [3x]
- High Pressure Diesel Fuel Injection Rail (2) - Remove
- Charge Air Cooler Bracket (1) - Remove
- NOTE:
If the injector can not be removed by hand, use the EN-52451 Injector Remover to aid in removal.
Pull out the 6 fuel injectors (2) with the EN-52451 Injector Remover (3) with J-6125-1B Slide Hammer (1).
High Pressure Diesel Fuel Injector (1) - Remove [6x]
- Fuel Injector Seal (2) - Remove and DISCARD [6x]
- Fuel Injector Washer (3) - Remove and DISCARD [6x]
- NOTE:
cover bolts and captured in the cover.
Camshaft Housing Cover Bolt (1) - Loosen [7x]
- Camshaft Housing Cover Bolt (2) - Loosen [3x]
- Camshaft Housing Cover Bolt (3) - Loosen [9x]
- Camshaft Housing Cover Bolt (4) - Loosen [7x]
Camshaft Housing (1) - Remove
- Camshaft Housing Gasket (2) Remove and DISCARD [2x]
- Clean around each of the glow plugs.
- CAUTION:
Ensure each glow plug is fully intact when removed from the cylinder head. A broken tip could remain within the combustion chamber, which may not be obvious during removal. Damage to the engine may result if a broken glow plug tip remains within the engine.
NOTE:- Glow plugs must be DISCARDED whenever removed, and replaced with NEW.
- If the cylinder head is removed, the accompanying glow plugs must be DISCARDED and replaced with NEW.
- Do not use power tools to install glow plugs.
- Use a suitable, commercially available glow plug socket.
- Cylinder head removal may be required to retrieve a broken tip.
Glow Plug (1) - Remove and DISCARD [6x]
- Inspect each glow plug tip and ensure the glow plug is not broken. If a broken tip is suspected, inspect the combustion chamber for the glow plug tip.
Timing Chain Cover Bolt (3) - Remove [4x]
- Timing Chain Cover Bolt (4) - Remove [2x]
- Timing Chain Upper Cover (1) @ Cylinder Head - Remove
- Engine Front Cover Locating Pin (2) @ Cylinder Head - Remove [2x]
Timing Chain Cover Bolt (1) - Remove
- Timing Chain Cover Bolt (2) - Remove [15x]
- Using a suitable tool at the locations indicated by the arrows to pry, loosen the timing chain lower cover carefully from the engine block.
Timing Chain Lower Cover (1) - Remove
- NOTE:
Use a suitable rubber or plastic mallet to remove the crankshaft rear oil seal.
Crankshaft Rear Oil Seal (4) - Remove and DISCARD
Timing Chain Tensioner (2) - Remove
- Timing Chain Tensioner Gasket (1) - Remove and DISCARD
Ensure EN-52586 Crankshaft Fixing Pin (1) is installed and locking the crankshaft.
Ensure that the camshaft notches (1) are in the 12 O'clock position.
- If the camshaft notches are not in the 12 O'clock position, remove the EN-52586 Crankshaft Fixing Pin and rotate the crankshaft until the camshaft notch stands in the 12 O'clock position, and the crankshaft aligns with the EN-52586 Crankshaft Fixing Pin locking location.
- Install EN-52586 Crankshaft Fixing Pin with the camshaft notches (1) in the 12 O'clock position.
Install the EN-52445-2 Camshaft Tool (1, 2) to the camshafts.
Camshaft Sprocket Bolt (3) - Remove and DISCARD
- Camshaft Position Sensor Exciter Wheel (1) - Remove
- Camshaft Sprocket (2) - Remove
Timing Chain Guide Bolt (2) - Remove [2x]
- Timing Chain Guide (1) - Remove
Secondary Timing Chain (1) - Remove
Camshaft Sprocket Bolt (1) - Remove and DISCARD
- Camshaft Sprocket (2) - Remove
Remove EN-52445-2 Camshaft Tool (1, 2) from the camshafts.
Timing Chain Tensioner Shoe Bolt (2) - Remove
- Timing Chain Guide (1) - Remove
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Install the EN-52445-1 Camshaft Tool (3) to the.
- Check that the tab (1) of the EN-52445-1 Camshaft Tool sits correctly under the camshaft bearing rear cap (2).
- Check that the pins (6) of the EN-52445-1 Camshaft Tool sit correctly in the camshafts (5).
- Loosely install the 6 bolts (4) of the EN-52445-1 Camshaft Tool.
Install the EN-52445-2 Camshaft Tool (1) on the camshafts.
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Hand tighten the 6 bolts (1) of the EN-52445-1 Camshaft Tool a half-turn each in sequence shown.
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Loosen the 16 bolts in sequence as shown (1).
- Camshaft Housing Bolt (1) - Remove [16x]
Install the 2 J-43301 Coil Pack Puller (1).
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Loosen the 6 bolts (1) of the EN-52445-1 Camshaft Tool a half-turn each in sequence shown, until disengaged from the cylinder head.
Camshaft Housing (1) - Remove - Use the special tool: J-43301 Coil Pack Puller (2)
- Camshaft Housing Gasket (3) - Remove and DISCARD [5x]
- Camshaft Housing Gasket (4) - Remove and DISCARD
- Remove the 2 J-43301 Coil Pack Puller (2).
Remove the EN-52445-2 Camshaft Tool (1, 2, 3) from the camshafts.
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Remove the EN-52445-1 Camshaft Tool (3) from the.
- NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
Remove the 24 valve rocker arms (1) from hydraulic valve lash adjusters (2).
Remove the 24 hydraulic valve lash adjuster (2) from the cylinder head.
Install the EN-47634 Holder (1) to the EN-956 Extension (4).
- Using EN-47634 Camshaft Sprocket Holder to hold the oil pump sprocket (2), loosen the oil pump drive bolt (3).
- Remove the EN-47634 Camshaft Sprocket Holder and the EN-956 Extension.
Oil Pump Drive Bolt (3) - Remove
- Remove the oil pump sprocket (2) and timing belt (1).
Push the timing chain guide (1) in direction of the arrow to compress the tensioner piston.
- Install one EN-52234 Timing Chain Tensioner Retaining Pin (2) to lock the timing chain tensioner in position.
- Timing Chain Tensioner Bolt (3) - Remove [2x]
- Timing Chain Tensioner (4) - Remove
Timing Chain Guide Bolt (2) - Remove [2x]
- Timing Chain Guide (1) - Remove
Timing Chain Guide (1) - Remove
Crankshaft Position Sensor Bolt (3) - Remove
- Crankshaft Position Sensor (2) - Remove
- Crankshaft Position Sensor Seal (1) - Remove and DISCARD
Install the EN-49979 Holder (1) with the EN-49979-100 Holder Pins (2) to the outer hole pattern.
- Install EN-49979 Holder (1) with EN-49979-100 Holder Adapter Pins (2) and EN-956-1 Extension (4) to hold the fuel injection pump driven sprocket.
- Fuel Injection Pump Bolt (3) - Loosen
- Remove the EN-49979 Holder, EN-49979-100 Holder Adapter Pins, and EN-956-1 Extension.
Fuel Injection Pump Bolt (1) - Remove and DISCARD
Install the EN-52448-3 nut (2) to the fuel injection pump driven sprocket (3).
- Install the EN-52448-2 screw (1) to the fuel injection pump driven sprocket (3).
- Using EN-52448-2 nut (2) and EN-52448-3 screw (3), press out the fuel injection pump sprocket (3).
- Hold the nut, and turn the screw pressing out the fuel injection pump sprocket (3).
Slide the fuel injection pump driven sprocket (1) back slightly and disengage the sprocket from the timing chain (2).
- Fuel Injection Pump Driven Sprocket (1) - Remove
- Remove the EN-52448-2 screw.
- Remove the EN-52448-3 nut.
Timing Chain (1) - Remove
Fuel Injection Pump Bolt (1) - Remove [3x]
High Pressure Diesel Fuel Pump (1) - Remove
- Fuel Pump Seal (2) - Remove and DISCARD
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Loosen the cylinder head bolts 17 in the sequence shown (1, 2).
- Cylinder Head Bolt (1) - Remove and DISCARD [14x]
- Cylinder Head Bolt (2) - Remove [3x]
Cylinder Head (1) - Remove
- Cylinder Head Gasket (2) - Remove and DISCARD
Oil Pan Bolt (1) - Remove [23x]
- NOTE:
Ensure that the two lower crankcase extension pins (3) do not get damaged while loosening.
Use the EN-37228 Separating Tool (1) to carefully loosen the lower oil pan (2) evenly all the way around. Avoid the locations near the lower crankcase extension pins.
Lower Oil Pan (1) - Remove and DISCARD
Disconnect the electrical connector. (1)
Oil Pump Bolt (1) - Remove [4x]
- Oil Pump (2) - Remove
- Oil Pump Gasket (3) - Remove and DISCARD [2x]
- NOTE:
Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
Lower Crankcase Extension Bolt - M6 (1) - Remove
- Lower Crankcase Extension Bolt - M6 (2) - Remove [12x]
- Lower Crankcase Extension Bolt - M6 (3) - Remove
- Lower Crankcase Extension Bolt - M8 (4) - Remove and DISCARD [7x]
- NOTE:
Ensure that the two lower crankcase extension pins (2, 4) do NOT get damaged while loosening.
Use the EN-37228 Separating Tool (3) to carefully loosen the lower crankcase extension (1) evenly all the way around. Avoid the lower crankcase extension pin locations.
- NOTE:
Pry carefully at the locations as shown (1, 3).
Lower Crankcase Extension (2) - Remove
- Upper Oil Pan Gasket (4) - Remove and DISCARD
- Oil Pump Gasket (5) - Remove and DISCARD
- NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate the location, direction, or orientation when necessary.
- The shear surfaces of the connecting rod and the connecting rod cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
Remove and DISCARD the 4 connecting rod bolts (3, 4) from cylinder 2 and cylinder 5.
- Remove the 2 connecting rod caps (2) from cylinder 2 and cylinder 5.
- Remove the 2 connecting rod lower bearings (1).
Push the 2 pistons (1, 2) with the 2 connecting rods out of cylinder 2 and cylinder 5.
- Remove the 2 connecting rod upper bearings (3, 4).
- Turn the crankshaft 120 degrees.
Remove and DISCARD the 4 connecting rod bolts (3, 4) from cylinder 1 and cylinder 6.
- Remove the 2 connecting rod caps (2) from cylinder 1 and cylinder 6.
- Remove the 2 connecting rod lower bearings (1).
Push the 2 pistons (1, 2) with the 2 connecting rods out of cylinder 1 and cylinder 6.
- Remove the 2 connecting rod upper bearings (3, 4).
- Turn the crankshaft 120 degrees.
Remove and DISCARD the 4 connecting rod bolts (4) from cylinder 3 and cylinder 4.
- Remove the 2 connecting rod caps (3, 5) from cylinder 3 and cylinder 4.
- Remove the 2 connecting rod lower bearings (1, 2).
Push the 2 pistons (1, 2) with the 2 connecting rods out of cylinder 3 and cylinder 4.
- Remove the 2 connecting rod upper bearings (3, 4).
Allow the oil to drain completely.
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.
Once the EN-52586 Crankshaft Fixing Pin (4) is installed, do not remove until all timing components have been installed.
Avoid prying close to the transmission locating pins.
Ensure that the pump shaft coupling is aligned vertically, parallel with the oil pump bolts.