OIL PUMP REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • w/DPF

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note

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


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. REMOVE ENGINE ASSEMBLY


    1. Remove the engine assembly from the vehicle Click here.

  4. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE

    Click here

  5. REMOVE GENERATOR ASSEMBLY


    1. B001YKL

      Remove the nut and bolt, and disconnect the generator positive (+) cable.

    2. B001XD3

      Remove the 3 bolts, 2 nuts and generator.

  6. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE

    Click here

  7. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B001WG7

      Remove the 2 bolts and No. 1 engine oil level dipstick guide.

  8. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE

    Click here

  9. DISCONNECT NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. B001XSB

      Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe.

  10. REMOVE STIFFENER INSULATOR RH (w/ Intercooler)


    1. B001X1E

      Remove the 2 bolts and stiffener insulator RH.

  11. DISCONNECT NO. 1 OIL COOLER HOSE

    B001YXEE03
    *1 No. 1 Hose
    *2 No. 2 Hose

  12. DISCONNECT NO. 2 OIL COOLER HOSE

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B001ZEY

      Remove the 3 bolts and V-ribbed belt tensioner bracket.

    2. B001ZF7

      Remove the bolt and No. 1 idler pulley.

    3. B001W6J

      Remove the 5 bolts and V-ribbed belt tensioner.

  14. REMOVE CRANKSHAFT PULLEY

    Click here

  15. REMOVE TIMING GEAR COVER SPACER (w/ Intercooler)


    1. B001WCY

      Remove the 2 bolts and timing gear cover spacer.

  16. REMOVE OIL FILTER ELEMENT

    Click here

  17. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. B001WVZ

      Disconnect the 2 wire harness clamps.

    2. B001YGI

      Remove the 3 bolts, 2 nuts and oil filter bracket.

    3. B001X14

      Remove the 2 O-rings.

  18. REMOVE ENGINE OIL LEVEL SENSOR


    1. B001XS2

      Remove the 4 bolts and engine oil level sensor.

    2. Remove the gasket.

  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B001YGF

      Remove the 10 bolts and 2 nuts.

    2. B001YM7

      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.

      Note

      Be careful not to damage the contact surfaces of the No. 1 and No. 2 oil pans.

  20. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B001ZCL

      Remove the 2 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  21. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. B001WP1E04
      *1 Oil Reflector Plate

      Remove the 20 bolts, 2 nuts and oil reflector plate.

      Note

      If the oil reflector plate is deformed, replace it.

      Tech Tips

      Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

    2. B001YUV

      Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

      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. B001YIF

      Remove the 3 O-rings.

    4. B001YYN

      Remove the cylinder block oil hole gasket.

  22. REMOVE OIL REGULATOR ASSEMBLY


    1. B001YRD

      Remove the 4 bolts and oil regulator.

  23. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B001ZNY

      Remove the 10 bolts.

    2. Remove the oil seal retainer by prying between the oil seal retainer and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE REAR CRANKSHAFT OIL SEAL

    Click here

  25. REMOVE OIL PUMP ASSEMBLY


    1. B001Y3M

      Remove the 4 bolts and oil pump.