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

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  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. A01BEQHE01

      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. A01BEQHE01

      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. A01BH1YE01

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

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. TYPE A:

      A01BFA6E01
      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:

      A01BGKUE01
      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

    A01BERQ

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  9. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A01BHAF

      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

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

    Click here

  13. REMOVE COMMON RAIL ASSEMBLY

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  14. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  15. REMOVE INJECTOR ASSEMBLY

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  16. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BBTF

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

    2. A01BDDQE02
      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. A01BF5DE05

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

  17. REMOVE NO. 2 TIMING BELT COVER


    1. A01BC0NE01

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

  18. REMOVE WATER PUMP ASSEMBLY


    1. A01BHZ7

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

  19. REMOVE CRANKSHAFT PULLEY


    1. A01BHJJE01

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

      SST
      09213-58014
      09330-00021
    2. A01BE2GE01

      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. A01BCRH

      Disconnect the vinyl tube from the oil pan.

    2. A01BEX0E02

      Remove the 22 bolts and 2 nuts.

    3. A01BD5SE04

      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. A01BD5SE04

      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. A01BGWK

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

  22. REMOVE TIMING GEAR COVER


    1. A01BDJ8E01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 14 bolts and 2 nuts.

    2. A01BHS4E01
      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. A01BCW4

      w/ DPF:

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

    4. A01BCHAE01

      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. A01BD07E01

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

      2. A01BDYNE02

        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. A01BATGE02

        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. A01BGMXE01

        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. A01BHO4E01

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

      2. A01BBF6E01

        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. A01BFW6E01

        Using SST, remove the oil seal.

        SST
        09308-10010
        09950-40011   ( 09957-04010 )
        09950-60010   ( 09951-00350 )
      2. A01BAUPE01

        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. A01BAH4

      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. A01BDX7

      Remove the injection gear.

  26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01BDK9

      Remove the No. 1 crankshaft position sensor plate.

  27. REMOVE CRANKSHAFT TIMING GEAR


    1. A01BDVUE01

      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. A01BCIR

      Remove the 2 bolts and idle gear thrust plate.

  29. REMOVE NO. 1 IDLE GEAR


    1. A01BB2RE01

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

    2. A01BGLIE01

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

      Note

      Be careful not to damage the gears.

    3. A01BG47E02
      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. A01BF16E01

      Using snap ring pliers, remove the shaft snap ring.

    5. A01BCCYE03
      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. A01BEA9E01

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

      Note

      Be careful not to damage the gear.

    7. A01BBDQE01

      Using snap ring pliers, remove the shaft snap ring.

    8. A01BCV7E05
      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. A01BA77E01

      Remove the No. 1 idle gear shaft.

  31. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A01BH33E01

      Remove the union bolt and 8 bolts.

    2. A01BH5PE02

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

    3. A01BDE1E01

      Remove the gasket.

    4. A01BEOUE03

      Remove the 2 O-rings.