OIL PUMP REMOVAL


  1. REMOVE ENGINE W/ TRANSAXLE

    Click here

  2. REMOVE TIMING BELT UPPER COVER


    1. A0138DM

      Remove the 5 bolts and timing belt upper cover.

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0136UU

      Using a "torx" socket wrench, remove the 3 screws.

    2. Remove the air cleaner cap sub-assembly.

    3. Remove the air filter element.

  4. REMOVE INTAKE AIR RESONATOR


    1. A0136RX

      Disconnect the intake air temperature sensor connector.

    2. A0137XK

      Loosen the air hose No.2 clamp.

    3. Using a "torx" socket wrench, remove the screw.

    4. Remove the bolt, intake air resonator and O-ring.

  5. REMOVE TURBO PRESSURE SENSOR


    1. A0137YA

      Disconnect the turbo pressure sensor connector.

    2. A0136M9

      Disconnect the turbo pressure sensor hose from the cylinder head cover.

    3. A01362M

      Remove the bolt and turbo pressure sensor.

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A0137UK

      Loosen the air hose No.1 clamp.

    2. Disconnect the PCV hose from the cylinder head cover.

    3. Using a "torx" socket wrench, remove the 2 screws.

    4. Remove the air cleaner case sub-assembly.

  7. REMOVE FUEL FILTER ASSEMBLY


    1. A0135ZW

      Disconnect the fuel return hose from the No.4 injector.

    2. A0135W0

      Disconnect the fuel temperature sensor connector.

    3. A0137NS

      Pinch the retainer as illustrated, then pull out the fuel hose from the fuel pump.

    4. Pinch the retainer as illustrated, then pull out the fuel return hose from the fuel pump.

    5. A013931

      Disconnect the fuel level warning switch connector.

    6. A01393H

      Disconnect the fuel heater hose connector (w/ fuel heater).

    7. A0136XL

      Using a "torx" socket wrench, remove the screw.

    8. Remove the 2 bolts, fuel filter, and fuel bracket with priming pump.

  8. DISCONNECT ENGINE WIRE NO.2


    1. A0138A5

      Disconnect the glow harness connector.

    2. A0135V2

      Disconnect the fuel pressure sensor connector.

    3. A0136C6

      Disconnect the 4 injector connectors and remove the engine wire No.2.

  9. REMOVE HEATER WATER OUTLET HOSE A


    1. A0137MH

      Using pliers, slide the clip to remove the heater water outlet hose A.

  10. REMOVE EGR COOLER WATER BY-PASS HOSE


    1. A0137WQ

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the water by-pass hose.

  11. REMOVE EGR VALVE ASSEMBLY


    1. A0136XY

      Disconnect the EGR valve connector.

    2. A0137SF

      Using a "torx" socket wrench, remove the 2 screws.

    3. A0136D4

      Remove the bolt and clamp from the EGR pipe.

    4. A01369N

      Remove the 2 bolts from the EGR valve.

    5. Remove the EGR valve assembly, gasket and O-ring.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A013789

      Disconnect the diesel throttle valve connector.

    2. A0136DL

      Remove the 10 bolts, cylinder head cover sub-assembly, gasket and 4 O-rings.

  13. REMOVE TURBO INSULATOR NO.1


    1. A0137BH

      Remove the 7 bolts and turbo insulator No.1.

  14. REMOVE MANIFOLD HEAT SHIELD


    1. A0138LO

      Remove the 2 bolts and manifold heat shield.

  15. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A0136ILE01

      Remove the 2 nuts and 2 exhaust manifold converter clamps.

    2. Remove the 2 nuts, exhaust manifold converter sub-assembly, catalytic converter support bracket, and converter separator insulator No.1.

  16. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

  17. REMOVE OIL LEVEL GAUGE GUIDE


    1. A0137BX

      Remove the bolt and oil level gauge guide.

    2. A013776

      Remove the 2 O-rings from the oil level gauge guide.

  18. REMOVE STUD BOLT


    1. A0138ZOE01

      Using a "trox" socket wrench (E7), remove the stud bolt.

  19. DISCONNECT WIRE HARNESS


    1. A0137P9E01

      Disconnect the engine oil pressure switch connector.

    2. A0138SIE01

      w/ Air Conditioning System:


      1. Disconnect the wire harness from the generator assembly.

      2. Disconnect the compressor connector.

  20. REMOVE V-RIBBED BELT TENSIONER SUB-ASSEMBLY


    1. A0137H7

      Remove the 3 bolts and V-ribbed belt tensioner sub-assembly.

  21. REMOVE GENERATOR ASSEMBLY (w/ Air Conditioning System)


    1. A0137E9E01

      Disconnect the generator connector.

    2. Remove the terminal cap.

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

    4. Remove the 4 bolts and generator assembly.

  22. REMOVE ALTERNATOR BRACKET NO.2 (w/ Air Conditioning System)


    1. A0137KY

      Remove the 2 nuts, 2 bolts and alternator bracket No.2.

  23. REMOVE GENERATOR ASSEMBLY (w/o Air Conditioning System)


    1. A013920

      Disconnect the generator connector.

    2. Remove the terminal cap.

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

    4. Remove the 4 bolts and generator assembly with generator bracket No.2.

    5. Using a hexagon socket wrench, remove the bolt and V-ribbed belt idler assembly No.1 from the generator bracket No.2.

    6. Remove the 2 bolts and generator bracket No.2 from the generator assembly.

  24. REMOVE CRANKSHAFT PULLEY


    1. A0137L7E01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Remove the bolt and crankshaft pulley.

  25. REMOVE TIMING BELT LOWER COVER


    1. A0135SJ

      Remove the 5 bolts and timing belt lower cover.

  26. REMOVE ENGINE MOUNT BRACKET


    1. A01374V

      Remove the 4 bolts and engine mount bracket.

  27. SET TIMING MARK


    1. A0136BR

      Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.

    2. A0137V1

      Check that the timing holes of the camshaft drive pulley and the cylinder head are aligned.

  28. REMOVE CRANK POSITION SENSOR


    1. A0136ZP

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

    3. Remove the bolt and crankshaft timing pulley support.

  29. REMOVE TIMING BELT


    1. A0135VS

      Remove the bolt and timing belt tensioner.

    2. Remove the timing belt.

  30. INSTALL ENGINE MOUNT BRACKET


    1. A0138R6

      Install the engine mount bracket with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  31. SEPARATE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A0136HV

      Attach the engine sling and hang the engine with the chain block.

    2. A01389H

      Remove the bolt, then separate the engine with transaxle assembly from the front suspension crossmember assembly.

  32. REMOVE STARTER ASSEMBLY


    1. A0138HDE01

      Remove the bolt and remove the wire harness clamp bracket.

    2. Remove the nut and disconnect the wire harness from terminal 30.

    3. Remove the nut and disconnect the wire harness from terminal 50.

    4. Using a hexagon wrench (6 mm), remove the 3 bolts and remove the starter.

  33. REMOVE MANUAL TRANSAXLE ASSEMBLY

    A01373ME01

    1. Remove the 7 bolts and manual transaxle from the engine.

      Tech Tips


      • Remove 3 A bolts from the transaxle side.

      • Remove 4 B bolts from the engine side.

  34. INSTALL CRANKSHAFT PULLEY


    1. A0138L0E01

      Install the crankshaft pulley with the bolt.

    2. Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    3. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    4. A0136QPE01

      Mark the top surface of the crankshaft pulley bolt with paint.

    5. Retighten the bolt by additional 190 degrees as shown in the illustration.

  35. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01386OE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021
    2. A01367I

      Remove the 6 bolts and flywheel sub-assembly.

  36. REMOVE CLUTCH COVER ASSEMBLY

    A0138RBE02

    1. Align the matchmark on the clutch cover with the one on the flywheel.

    2. Loosen each set bolt by one turn at a time until the spring tension is released.

    3. Remove the set bolts and the clutch cover.

      Note

      Do not drop the clutch disc.

  37. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Do not allow any oil or foreign matter to adhere to the lining part of the clutch disk or the surfaces of the pressure plate and flywheel.

  38. REMOVE OIL PAN SUB-ASSEMBLY


    1. A0135XE

      Remove the 2 nuts and 15 bolts.

    2. A0135Z6

      Using an oil pan cutter, remove the oil pan sub-assembly from the cylinder block assembly.

      SST
      09032-00100

  39. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0136C0

      Using a hexagon socket wrench, remove the 3 bolts, oil strainer sub-assembly and gaskets.

  40. REMOVE OIL PUMP ASSEMBLY


    1. A0136LT

      Remove the 8 bolts.

    2. A0138TSE01

      Remove the oil pump assembly by prying between the oil pump assembly and cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A0137G5E01

      Remove the O-ring from the oil pump assembly.

  41. REMOVE CRANK OIL SEAL


    1. A01388PE01

      Using a screwdriver with its tip taped, pry out the crank oil seal.

      Tech Tips

      Tape the screwdriver tip before use.