OIL PUMP (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. INSTALL ENGINE STAND


    1. Install the engine to an engine stand with the bolts.

    2. Remove the engine sling device and chain block.

    3. Remove the 2 bolts and 2 engine hangers.

  3. REMOVE VANE PUMP ASSEMBLY


    1. B007QBUE01

      Remove the 2 nuts and the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  4. REMOVE VACUUM PUMP ASSEMBLY


    1. B007QBUE01

      Remove the 2 nuts and the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  5. REMOVE TIMING BELT

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


    1. B007SOTE01

      Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. TYPE A:

      B007RV2E01
      Text in Illustration
      *1 Clamp *2 Wire Harness Clamps (A)
      *3 Wire Harness Clamps (B) *4 Wire Harness Clamps (C)

      1. Detach the 2 wire harness clamps (B, C).

      2. Disconnect the crankshaft position sensor connector.

      3. Detach the crankshaft position sensor connector from the No. 1 vacuum transmitting pipe.

      4. Remove the clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Do not reuse the clamp.

      5. Remove the bolt and crankshaft position sensor.

      6. Remove the wire harness clamp (A) from the crankshaft position sensor.

    2. TYPE B:

      B007OYHE01
      Text in Illustration
      *1 Clamp *2 Bracket (Clamp)
      *3 Wire Harness Clamps (A) *4 Wire Harness Clamps (B)
      *5 Wire Harness Clamps (C) - -

      1. Detach the 2 wire harness clamps (B, C).

      2. Disconnect the crankshaft position sensor connector.

      3. Detach the crankshaft position sensor connector from the No. 1 vacuum transmitting pipe.

      4. Remove the clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Do not reuse the clamp.

      5. Remove the bolt and bracket (clamp).

      6. Remove the bolt and crankshaft position sensor.

      7. Remove the wire harness clamp (A) from the crankshaft position sensor.

      8. Detach the 2 wire harness clamps from the bracket (clamp).

  8. REMOVE CAMSHAFT POSITION SENSOR

    B007VA3

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  9. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. B007VDW

      Disconnect the oil pressure switching valve connector.

    2. Remove the bolt and oil pressure switching valve.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  11. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  12. REMOVE EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY

    Click here

  13. REMOVE COMMON RAIL ASSEMBLY

    Click here

  14. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  15. REMOVE INJECTOR ASSEMBLY

    Click here

  16. REMOVE CAMSHAFT TIMING PULLEY


    1. B007SGO

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

    2. B007RSCE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the camshaft timing pulley and key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. B007RKAE05

      Rotate the crankshaft approximately 90° counterclockwise from TDC to lower the piston.

  17. REMOVE NO. 2 TIMING BELT COVER


    1. B007R1OE01

      Remove the nut, 4 bolts and No. 2 timing belt cover.

  18. REMOVE WATER PUMP ASSEMBLY


    1. B007UVA

      Remove the 5 bolts, 2 nuts, water pump and gasket.

  19. REMOVE CRANKSHAFT PULLEY


    1. B007T0QE01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. B007R5AE01

      Using SST, remove the pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  20. REMOVE OIL PAN SUB-ASSEMBLY


    1. B007RQ5

      Disconnect the vinyl tube from the oil pan.

    2. B007P4QE02

      Remove the 22 bolts and 2 nuts.

    3. B007SVAE04

      w/ DPF:

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer, and then remove the oil pan.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing gear case, or for the area between the oil pan and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

    4. B007SVAE04

      w/o DPF:

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block stiffening plate, cut through the applied sealer, and then remove the oil pan and cylinder block stiffening plate.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing gear case, or for the area between the oil pan and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  21. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B007Q4W

      Remove the 2 bolts, 2 nuts, oil strainer and gasket.

  22. REMOVE TIMING GEAR COVER


    1. B007PSYE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 14 bolts and 2 nuts.

    2. B007TBYE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

      Note

      Be careful not to drop the injection gear.

    3. B007Q22

      w/ DPF:

      Remove the 3 O-rings from the timing gear case.

    4. B007SMLE01

      w/o DPF:

      Remove the O-rings from the timing gear case.

  23. REMOVE TIMING GEAR CASE OIL SEAL

    Tech Tips

    There are 2 methods to remove the oil seal.


    1. If the timing gear cover is removed from the cylinder block:


      1. B007S25E01

        Using a screwdriver and hammer, tap out the oil seal.

      2. B007QVEE02

        Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09223-15020
        09502-12010
        09950-70010   ( 09951-07100 )

      3. Apply MP grease to the lip of the oil seal.

    2. If the timing gear cover is installed to the cylinder block:


      1. B007VOBE02

        Using a knife, cut through the lip of the oil seal.

      2. Using a screwdriver, pry out the oil seal.

        Note

        Be careful not to damage the crankshaft.

      3. B007TP5E01

        Apply MP grease to the lip of the oil seal.

      4. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09223-15020
        09502-12010
        09950-70010   ( 09951-07100 )

  24. REMOVE TIMING GEAR COVER OIL SEAL

    Tech Tips

    There are 2 methods to remove the oil seal.


    1. If the timing gear cover is removed from the cylinder block:


      1. B007R4DE01

        Using a screwdriver and hammer, tap out the oil seal.

      2. B007RU2E01

        Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

        SST
        09214-76011

      3. Apply MP grease to the lip of the oil seal.

    2. If the timing gear cover is installed to the cylinder block:


      1. B007QZJE01

        Using SST, remove the oil seal.

        SST
        09308-10010
        09950-40011   ( 09957-04010 )
        09950-60010   ( 09951-00350 )
      2. B007TJKE01

        Apply MP grease to the lip of a new oil seal.

      3. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing gear cover edge.

        SST
        09214-76011

  25. REMOVE INJECTION GEAR


    1. B007QTI

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.

    2. B007U8O

      Remove the injection gear.

  26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B007QM5

      Remove the No. 1 crankshaft position sensor plate.

  27. REMOVE CRANKSHAFT TIMING GEAR


    1. B007T7HE01

      Using SST, remove the crankshaft timing gear.

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

  28. REMOVE IDLE GEAR THRUST PLATE


    1. B007UDN

      Remove the 2 bolts and idle gear thrust plate.

  29. REMOVE NO. 1 IDLE GEAR


    1. B007VGHE01

      Remove the No. 1 idle gear together with the No. 1 and No. 2 idle sub gears.

    2. B007OH4E01

      Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    3. B007POJE02
      Text in Illustration
      *1 Service Bolt

      Using SST, turn the No. 1 idle sub gear clockwise and remove the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
    4. B007UAGE01

      Using snap ring pliers, remove the shaft snap ring.

    5. B007UWWE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 1 idle sub gear and idle gear spring.

    6. B007PMTE01

      Remove the No. 1 idle gear and set it in a vise.

      Note

      Be careful not to damage the gear.

    7. B007OSBE01

      Using snap ring pliers, remove the shaft snap ring.

    8. B007S0VE05
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Remove the wave washer, No. 2 idle sub gear and idle gear spring.

  30. REMOVE NO. 1 IDLE GEAR SHAFT


    1. B007Q3LE01

      Remove the No. 1 idle gear shaft.

  31. REMOVE TIMING GEAR CASE ASSEMBLY


    1. B007W7JE01

      Remove the union bolt and 8 bolts.

    2. B007U1SE02

      Pry the timing gear case at the location shown in the illustration and remove the timing gear case.

    3. B007UTFE01

      Remove the gasket.

    4. B007OYWE03

      Remove the 2 O-rings.