OIL PUMP (w/o 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. REMOVE ENGINE ASSEMBLY

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  2. INSTALL ENGINE STAND

  3. REMOVE VANE PUMP ASSEMBLY


    1. A003C7IE01

      Remove the 2 nuts and the vane pump assembly.

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

  4. REMOVE TIMING GEAR COVER INSULATOR


    1. A003G51

      Remove the bolt and timing gear cover insulator.

  5. REMOVE VACUUM PUMP ASSEMBLY


    1. A003FMC

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

  6. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the wire harness clamp.

    2. A003GVM

      Remove the 6 bolts, 6 washers and timing belt cover.

  7. REMOVE TIMING BELT

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  8. REMOVE CRANKSHAFT POSITION SENSOR

    A003DF5

    1. Disconnect the crankshaft position sensor connector.

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

    3. A003CQ5

      Separate the 3 wire harness clamps.

    4. Remove the bolt and the crankshaft position sensor.

  9. REMOVE CAMSHAFT POSITION SENSOR

    A003HO8

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. w/o DPF:


      1. A003CKM

        Disconnect the diesel turbo pressure sensor connector and vacuum switching valve connector.

      2. Remove the bolt and disconnect the wire harness clamp.

    2. Disconnect the 2 diesel throttle body connectors.

    3. A003I7KE01

      Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  11. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  12. REMOVE EGR COOLER ASSEMBLY

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  13. REMOVE COMMON RAIL ASSEMBLY

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  14. REMOVE FUEL SUPPLY PUMP ASSEMBLY

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  15. REMOVE INJECTOR ASSEMBLY

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  16. REMOVE CAMSHAFT TIMING PULLEY


    1. A003B5E

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

    2. A003AJEE01

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. A003BHNE02

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

  17. REMOVE NO. 2 TIMING BELT COVER


    1. A003DMBE01

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

  18. REMOVE WATER PUMP ASSEMBLY


    1. A003G4T

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

  19. REMOVE CRANKSHAFT PULLEY


    1. A003D60E01

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A003FX4E01

      Using SST, remove the crankshaft pulley.

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

      Note

      Apply oil or grease to the threads and tip of SST (center bolt) before using it.

  20. REMOVE ENGINE OIL LEVEL SENSOR

    A003CD2

    1. Disconnect the engine oil level sensor connector.

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

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. A003AUT

      Disconnect the vinyl tube from the oil pan.

    2. A003CALE02

      Remove the 22 bolts and 2 nuts.

    3. A003BSSE04

      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 an oil pan seal cutter for the timing gear case side and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  22. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A003AQ9

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

  23. 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. A003CRY

      Remove the 14 bolts and 2 nuts.

    2. A003EI5

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

      Note

      Do not damage the contact surface.

    3. A003F6QE03

      Remove the O-ring from the timing gear case.

    4. A003C47

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

  24. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A003HHS

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

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


    1. A003HCY

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

  26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A003FCQE01

      Remove the No. 1 crankshaft position sensor plate.

  27. REMOVE INJECTION GEAR


    1. A003BM0

      Remove the injection gear.

  28. REMOVE CRANKSHAFT TIMING GEAR


    1. A003D4KE02

      Using SST, remove the crankshaft timing gear.

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

  29. REMOVE IDLE GEAR THRUST PLATE


    1. A003G17

      Remove the 2 bolts and idle gear thrust plate.

  30. REMOVE NO. 1 IDLE GEAR


    1. A003DDP

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

      Note

      Make sure that the No. 2 idle sub gear and No. 1 idle gear are correctly fitted to each other.

  31. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A003CEJ

      Remove the No. 1 idle gear shaft.

  32. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A003ADF

      Remove the union bolt and 8 bolts.

    2. A003I1NE02

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

      Note

      Do not drop the driven rotor.

    3. A003DHDE02

      Remove the gasket from the timing gear case.

    4. A003GH4E01

      Remove the driven rotor from the timing gear case.

    5. A003DSXE03

      Remove the 2 O-rings from the cylinder block.