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.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  3. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  5. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01DNWCE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  6. REMOVE ENGINE ASSEMBLY

    Click here

  7. INSTALL ENGINE TO ENGINE STAND

  8. REMOVE TIMING BELT

    Click here

  9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  10. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  11. REMOVE INJECTOR ASSEMBLY

    Click here

  12. REMOVE GENERATOR ASSEMBLY


    1. A01DU38

      Remove the 2 bolts and generator.

  13. REMOVE GENERATOR BRACKET


    1. A01DNLP

      Remove the bolt and generator bracket.

  14. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01DSQ2

      Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  15. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01DS8Y

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  16. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DTSI

      Remove the bolt and camshaft position sensor.

  17. REMOVE CRANKSHAFT POSITION SENSOR


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

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

      A01DTTGE01
      Text in Illustration
      *1 Clamp *2 Bracket (Clamp)
      *3 Wire Harness Clamps (A) *4 Wire Harness Clamps (B)

  18. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A01DR2J

      Remove the bolt and oil pressure switching valve.

  19. REMOVE VACUUM PUMP ASSEMBLY


    1. Remove the bolt and bracket.

    2. A01DU2OE01

      Remove the 2 nuts, vacuum pump and 2 O-rings.

  20. REMOVE VANE PUMP ASSEMBLY


    1. A01DSPC

      Remove the 2 nuts, vane pump and O-ring.

  21. REMOVE CRANKSHAFT PULLEY COVER


    1. A01DPSQ

      Remove the 2 bolts and crankshaft pulley cover.

  22. REMOVE CRANKSHAFT PULLEY


    1. A01DMRSE01

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

      SST
      09213-58014
      09330-00021
    2. A01DLY5E01

      Using SST, remove the pulley bolt and crankshaft pulley.

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

  23. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01DTF1

      Remove the bolt, nut and No. 1 vacuum transmitting pipe.

  24. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. A01DMUC

      Remove the 4 bolts and No. 1 oil pan cover.

  25. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DT9YE01

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

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  26. REMOVE NO. 2 TIMING BELT COVER


    1. A01DNYW

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

  27. REMOVE WATER PUMP ASSEMBLY


    1. A01DSBV

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

  28. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump.


    1. A01DOJD

      Remove the 14 bolts and 2 nuts.

    2. A01DNNZ

      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. A01DLW6

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

  29. REMOVE INJECTION GEAR


    1. A01DRYJ

      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. A01DMNQ

      Remove the injection gear.

  30. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01DUA0

      Remove the No. 1 crankshaft position sensor plate.

  31. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DLTCE01

      Using SST, remove the crankshaft timing gear.

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

  32. REMOVE IDLE GEAR THRUST PLATE


    1. A01DRDD

      Remove the 2 bolts and idle gear thrust plate.

  33. REMOVE NO. 1 IDLE GEAR


    1. A01DQH5

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

  34. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01DS7I

      Remove the No. 1 idle gear shaft.

  35. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01DSFD

      Remove the 11 bolts and 2 nuts.

    2. A01DR9I

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

  36. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01DQC8

      Remove the 2 nuts, oil strainer and gasket.

  37. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01DU8F

      Remove the 22 bolts and 2 nuts.

    2. A01DSA6E02
      Text in Illustration
      *A LH Side
      *B RH Side
      *a Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01DME3

      Remove the gasket.

  38. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A01DQ4U

      Remove the union bolt and 8 bolts.

    2. A01DUGE

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

    3. A01DNXAE03

      Remove the 2 O-rings.