OIL PUMP REMOVAL


  1. REMOVE ENGINE ASSEMBLY

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  2. 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.

  3. REMOVE TIMING BELT COVER NO.1


    1. Remove the wire harness clamp.

    2. A01BHT6

      Remove the 6 bolts and timing belt cover No.1.

  4. REMOVE TIMING BELT


    1. A01BB9ZE01

      Turn the crankshaft in the clockwise direction and align the timing marks as shown in the illustration.

    2. A01BHFH

      Uniformly loosen the 2 bolts, and remove the chain tensioner assembly No.1.

    3. Remove the timing belt.

  5. REMOVE FAN PULLEY


    1. Remove the 4 nuts and fan pulley.

  6. REMOVE EGR PIPE SUB-ASSEMBLY NO.1.


    1. A01BGWP

      Disconnect the fuel pressure sensor connector.

    2. A01BD88

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  7. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  8. REMOVE INJECTION PIPE

    SST
    09023-12701

    1. Remove the injection pipe.


      1. A01BC89

        Remove the 2 nuts and injection pipe clamp No.3.

      2. A01BFG2

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Using SST, remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  10. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01BCD7

      Remove the 4 bolts.

    2. Remove the camshaft timing pulley flange No.2 and pump drive shaft pulley.

    3. A01BFRE

      Using SST, remove the supply pump gear set nut and O-ring while holding the crankshaft pulley.

      SST
      09213-58013
      09330-00021
    4. A01BGD8

      Disconnect the 2 fuel hoses.

    5. Disconnect the 2 connectors and wire harness.

    6. Loosen the 2 nuts as shown in the illustration.

    7. A01BA4CE01

      Using SST, disengage the supply pump from the supply pump gear.

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

    8. Remove the 2 nuts and supply pump from the engine.

    9. Remove the O-ring from the supply pump.

    10. Remove the pulley key from the supply pump.

  11. REMOVE COMPRESSOR BRACKET


    1. A01BFLCE01

      Remove the 4 bolts and compressor bracket.

  12. REMOVE IDLE PULLEY ASSEMBLY


    1. Remove the bolt, washers and idle pulley assembly.

  13. REMOVE GENERATOR BRACKET


    1. Remove the 2 bolts and generator bracket.

  14. REMOVE GENERATOR ASSEMBLY


    1. A01BCVDE01

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the bolt and generator assembly.

  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. Remove the 4 bolts and belt tensioner assembly.

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


    1. A01BH1Y

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

  17. REMOVE CRANKSHAFT PULLEY


    1. A01BCCZE01

      Remove the bolt holding the crankshaft with SST.

      SST
      09213-58013
      09330-00021

    2. Insert the service bolt.

    3. A01BATVE01

      Remove the crankshaft pulley with SST.

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

  18. REMOVE VACUUM PUMP ASSEMBLY


    1. A01BDP4

      Slide the clip and disconnect the 2 vacuum hoses from the vacuum pump.

    2. Remove the union bolt, vacuum pump union and 2 gaskets.

    3. A01BDDZ

      Remove the 2 nuts and pull out the vacuum pump from the engine.

    4. Remove the 2 O-rings.

  19. REMOVE CAMSHAFT POSITION SENSOR


    1. A01BERQ

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  20. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01BB55

      Disconnect the crankshaft position sensor connector.

    2. Separate the connector from the vacuum pipe No.1.

    3. A01BD2A

      Separate the 3 wire harness clamps.

    4. Remove the bolt and the crankshaft position sensor.

  21. REMOVE ENGINE OIL LEVEL SENSOR


    1. Remove the 4 bolts and engine oil level sensor.

  22. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01BASY

      Remove the oil filler cap from the cylinder head cover.

  23. REMOVE NOZZLE HOLDER SEAL


    1. A01BBWW

      Using a screwdriver, remove the holder seals by prying the portion between the holder seal and the cutout part of the cylinder head.

  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BAWTE01

      Remove the 10 bolts, 2 nuts, cylinder head cover and the cylinder head cover gasket.

    2. A01BGWS

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  25. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BBTF

      Remove the bolt for the camshaft timing pulley by holding the camshaft with a wrench.

    2. A01BDDQE01

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. A01BF5DE05

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

  26. REMOVE TIMING BELT COVER NO.2


    1. A01BC0N

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

  27. REMOVE WATER PUMP ASSEMBLY


    1. A01BHZ7

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

  28. REMOVE TIMING GEAR CASE


    1. A01BCGW

      Remove the 14 bolts and 2 nuts.

    2. A01BCBA

      Pry the gear case in the location shown in the illustration.

      Note

      Do not damage the contact surface.

    3. A01BAH4

      Secure the idler sub-gears to the idler gear with a service bolt.

    4. A01BDX7

      Remove the supply pump gear.

    5. A01BGX1E01

      Remove the O-ring.

  29. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1


    1. A01BDK9

      Remove the crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR


    1. A01BD9IE01

      Using SST, remove the crankshaft timing gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

  31. REMOVE IDLE GEAR THRUST PLATE


    1. A01BCIR

      Remove the 2 bolts and thrust plate.

  32. REMOVE IDLE GEAR NO.1


    1. A01BHPR

      Turn the sub gear and align the gear teeth of the idle main gear and sub gear.

    2. Remove the idle gear and sub gear.

  33. REMOVE IDLE GEAR SHAFT NO.1


    1. A01BDKJ

      Remove the idle gear shaft.

  34. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A01BCA4

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

  35. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A01BHMF

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

  36. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the drain plug and gasket.

    2. A01BEX0E01

      Remove the 22 bolts and 2 nuts.

    3. A01BC1GE01

      Insert the blade of SST between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note


      • Do not use SST for the timing belt case side and rear oil seal retainer.

      • Do not damage the oil pan flange.

  37. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01BGWK

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

  38. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A01BEE2

      Remove the union bolt and 8 bolts.

    2. A01BH5PE01

      Pry the gear case in the location shown in the illustration, remove the gear case.

      Note

      Do not drop the oil pump rotor.

    3. A01BDE1

      Remove the driven rotor and gasket.

    4. A01BH8W

      Remove the stud bolt.

    5. A01BBCJ

      Remove the 2 O-rings.