Engine Removal
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the wiring and terminals, unplug the wiring connectors carefully while holding the connector portion.
  • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
  1. Secure the hood in the wide open position (support rod in the lower hole).
  1. Disconnect the negative cable from the battery first, then disconnect the positive cable.
  1. Remove the battery.
  1. Remove the engine cover.
  1. Remove the air flow tube.
  1. Remove the harness clamp (A), then remove the two bolts (B) securing the clutch line bracket.
  1. Remove the harness clamp (A).
  1. Remove the battery base (B), then remove the battery base bracket (C).
  1. Remove the harness clamp (A) and the air cleaner housing bracket (B), then remove the bracket (C).
  1. Remove the battery cables (A) from the under-hood fuse/relay box.
  1. Disconnect the engine wire harness connectors (B).
  1. Remove the intercooler outlet hose.
  1. Remove the shift cable bracket.
  1. Remove the fuel hose.
  1. Remove the fuel return hose (A) and brake booster vacuum hose (B).
  1. Remove the steering joint cover (A).
  1. Make a reference mark (B) across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt (C), then disconnect the steering joint from the steering gearbox pinion shaft (D).
  1. Remove the expansion tank cap.
  1. Raise the vehicle on the hoist to full height.
  1. Remove the front wheels.
  1. Remove the engine undercover.
  1. Disconnect the exhaust gas temperature (EGT) sensor 2 connector (A), and remove the diesel particulate filter (DPF) differential pressure hoses (B), then remove the DPF (C) (with DPF).
  1. Remove the catalytic converter/exhaust pipe A assembly (without DPF).
  1. Remove the driveshafts. Coat all precision-finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
  1. Disconnect the connectors from the steering gearbox.
  1. Loosen the bands (A) securing the turbocharger outlet hose and intercooler intake hose, and remove the intercooler intake hose (B), then remove the intercooler intake pipe mounting bolts (C).
  1. Remove the intercooler intake pipe bracket (D), then remove the intercooler intake pipe (E).
  1. Lower the vehicle on the hoist.
  1. Remove the A/C line from the clamp (A), and remove the water bypass hose (B).
  1. Remove the A/C compressor.
  1. Remove the heater hoses.
  1. Attach the chain hoist using the sling belt and karabiner to the engine/transmission as shown.
    NOTE:
    • The sling belt must use the one that the load of 1,000 kg (2,204 lbs) or more can be endure.
    • The karabiner must use the one that the load of 500 kg (1,102 lbs) or more can be endure.
  1. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
  1. Remove the lower torque rod.
  1. Remove the subframe.
  1. Make sure the hoist brackets are positioned properly. Lower the vehicle on the hoist.
  1. Remove the side engine mount upper bracket mounting bolt and nuts (A).
  1. Remove the ground cable (B).
  1. Remove the transmission mounting bolt and nuts (A).
  1. Remove the ground cable (B).
  1. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
  1. Slowly lower the engine/transmission assembly about 150 mm (6 in.). Check once again that all hoses and electrical wiring are disconnected and free from the engine/transmission, then lower it all the way.
  1. Disconnect the chain hoist from the engine/ transmission assembly.
  1. Raise the vehicle all the way, and remove the engine/transmission assembly from under the vehicle.