OIL PUMP REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

PROCEDURE


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE NO. 3 ENGINE COVER BRACKET


    1. B001ETP

      Remove the 2 bolts and No. 3 engine cover bracket from the No. 2 engine cover bracket and engine cover bracket.

  3. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  4. REMOVE ENGINE WIRE

  5. REMOVE AIR TUBE ASSEMBLY

    Click here

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  7. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  8. REMOVE DIFFERENTIAL PRESSURE SENSOR

    Click here

  9. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    Click here

  10. REMOVE NO. 1 VACUUM PIPE

    Click here

  11. REMOVE NO. 2 VACUUM PIPE

    Click here

  12. REMOVE PIPE CLAMP

    Click here

  13. REMOVE ENGINE COVER BRACKET

    Click here

  14. REMOVE GAS FILTER

    Click here

  15. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  16. REMOVE EGR VALVE BRACKET

    Click here

  17. REMOVE NO. 2 EGR PIPE

    Click here

  18. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  19. REMOVE CONNECTING WIRE

    Click here

  20. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  21. REMOVE VACUUM CONTROL VALVE SET

    Click here

  22. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  23. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  24. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  25. REMOVE NO. 2 FUEL PIPE

    Click here

  26. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  27. REMOVE MANIFOLD STAY

    Click here

  28. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  29. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  30. REMOVE NO. 2 FUEL HOSE

    Click here

  31. REMOVE NO. 1 FUEL HOSE

    Click here

  32. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  33. REMOVE NO. 3 FUEL PIPE

    Click here

  34. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  35. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  36. REMOVE INTAKE MANIFOLD

    Click here

  37. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  38. REMOVE NO. 1 FUEL PIPE

    Click here

  39. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  40. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  41. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  42. REMOVE HOSE BRACKET

    Click here

  43. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  44. REMOVE PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  45. REMOVE PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  46. REMOVE NO. 5 WATER BY-PASS HOSE

    Click here

  47. REMOVE NO. 4 WATER BY-PASS HOSE

    Click here

  48. REMOVE NO. 1 INJECTOR HOLDER

    Click here

  49. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  50. REMOVE AIR FUEL RATIO SENSOR

    Click here

  51. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  52. REMOVE NO. 1 TURBO INSULATOR

    Click here

  53. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

    Click here

  54. REMOVE EXHAUST PIPE SUPPORT STAY

    Click here

  55. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  56. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  57. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  58. REMOVE NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  59. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  60. REMOVE TURBOCHARGER STAY

    Click here

  61. REMOVE TURBO OIL OUTLET PIPE

    Click here

  62. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  63. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  64. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  65. REMOVE WATER OUTLET SUB-ASSEMBLY

    Click here

  66. REMOVE WATER INLET

    Click here

  67. REMOVE THERMOSTAT

    Click here

  68. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B001DG3

      Remove the bolt and No. 1 idler pulley sub-assembly from the generator bracket sub-assembly.

  69. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B001I8Z

      Remove the 3 bolts and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.

  70. REMOVE VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  71. REMOVE CRANKSHAFT PULLEY COVER

    Click here

  72. REMOVE CRANKSHAFT PULLEY

    Click here

  73. REMOVE NO. 1 WATER HOSE CLAMP BRACKET

    Click here

  74. REMOVE NO. 1 ENGINE HANGER

    Click here

  75. REMOVE GENERATOR BRACKET SUB-ASSEMBLY

    Click here

  76. REMOVE INJECTOR ASSEMBLY

    Click here

  77. REMOVE NOZZLE HOLDER GASKET

    Click here

  78. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  79. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B001DZZ

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      B001CHY Bolt
      B001DEF Nut
      B001HIB Nozzle Holder Clamp Seat
    2. B001GLRE02
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  80. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  81. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B001H8Z

      Remove the 2 nuts and 11 bolts.

      Text in Illustration
      B001CHY Bolt
      B001DEF Nut
    2. B001CJL

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly, cut off the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.

      • Be careful not to damage the oil pan sub-assembly flange.

  82. REMOVE OIL PAN SUB-ASSEMBLY


    1. B001D1F

      Remove the 2 nuts and 23 bolts.

      Text in Illustration
      B001CHY Bolt
      B001DEF Nut
    2. B001CJL

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

      • Be careful not to damage the cylinder block sub-assembly flange.

  83. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  84. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  85. REMOVE TIMING CHAIN COVER PLATE

    Click here

  86. REMOVE SUPPLY PUMP ASSEMBLY

    Click here

  87. REMOVE INJECTION PUMP INSULATOR

    Click here

  88. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B001HYC

      Remove the 20 bolts from the timing chain cover sub-assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the points in the illustration.

      B001F6QE02
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain cover sub-assembly and timing chain case assembly.

    3. B001CO1

      Remove the timing chain case gasket from the timing chain case assembly.

  89. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B001FUDE02
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pull out the front crankshaft oil seal.

      Note

      Do not damage the surface of the front crankshaft oil seal press fit hole.

  90. INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR


    1. B001DDQ

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.3 mm (0.000787 to 0.0118 in.)
      Maximum gear backlash
      0.42 mm (0.0165 in.)

      If the gear backlash is more than the maximum, replace the timing chain case assembly or oil pump drive gear.

  91. REMOVE OIL PUMP DRIVE GEAR


    1. B001CBS

      Remove the oil pump drive gear from the crankshaft.

  92. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

  93. REMOVE NO.1 BALANCE SHAFT THRUST PLATE

    Click here

  94. REMOVE BALANCE SHAFT TIMING SPROCKET, BALANCE SHAFT GEAR SUB-ASSEMBLY AND NO. 3 CHAIN SUB-ASSEMBLY

    Click here

  95. REMOVE TIMING CHAIN GUIDE

    Click here

  96. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  97. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    Click here

  98. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  99. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  100. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  101. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    Click here

  102. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  103. REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY

    Click here

  104. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  105. REMOVE TIMING CHAIN CASE ASSEMBLY


    1. B001DN1

      Remove the 15 bolts from the timing chain case assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain case assembly by prying the points in the illustration.

      B001CPQE01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain case assembly, cylinder head sub-assembly and cylinder block sub-assembly.

    3. B001GY2

      Remove the 4 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.