OIL PUMP REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL ENGINE TO ENGINE STAND

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  2. REMOVE GENERATOR ASSEMBLY

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  3. REMOVE VACUUM PUMP ASSEMBLY


    1. A012M66

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump assembly.

    3. Remove the 2 O-rings from the vacuum pump assembly.

  4. REMOVE IDLER PULLEY COVER PLATE


    1. A012I0OC03
      *a Tape

      Using a screwdriver, remove the idler pulley cover plate.

      Tech Tips

      Tape the screwdriver tip before use.

  5. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A012MYT

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

  6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A012MQRC01
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley Sub-Assembly

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly.

  7. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A012H26

      Remove the bolt and No. 4 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 4 water by-pass pipe.

  8. REMOVE ENGINE MOUNTING BRACKET


    1. A012JFE

      Remove the 4 bolts, 2 nuts and engine mounting bracket.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A012M0Q

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

      Note

      As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during removal.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  11. REMOVE NO. 7 WATER BY-PASS HOSE

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  12. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  13. REMOVE EGR VALVE BRACKET

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  14. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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  15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  17. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  18. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  19. REMOVE NO. 4 FUEL HOSE

    A012LO3

    1. Slide the 2 clips and remove the No. 4 fuel hose.

  20. REMOVE COMMON RAIL ASSEMBLY

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  21. REMOVE INTAKE MANIFOLD INSULATOR

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  22. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A012K17

      Disconnect the vacuum hose.

    2. Remove the bolt and diesel turbo pressure sensor.

  23. REMOVE NO. 1 GAS FILTER

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  24. REMOVE GAS FILTER BRACKET

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  25. REMOVE ENGINE COVER BRACKET

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  26. REMOVE NO. 2 INTAKE MANIFOLD

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  27. REMOVE INTAKE MANIFOLD

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  28. REMOVE WATER BY-PASS HOSE

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  29. REMOVE OIL COOLER ASSEMBLY

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  30. REMOVE NO. 6 WATER BY-PASS HOSE

    A012G1J

    1. Slide the clip and remove the No. 6 water by-pass hose from the outlet water pipe.

  31. REMOVE NO. 8 WATER BY-PASS HOSE

    A012JVO

    1. Slide the clip and remove the No. 8 water by-pass hose from the outlet water pipe.

  32. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A012KAZ

      Remove the 2 bolts and No. 3 water by-pass pipe.

    2. Remove the O-ring from the No. 3 water by-pass pipe.

  33. REMOVE NO. 1 TURBO OIL PIPE


    1. A012KE0

      Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.

  34. REMOVE NO. 1 OIL COOLER BRACKET


    1. A012J2CC01
      A012L0C Nut

      Remove the 6 bolts, nut and No. 1 oil cooler bracket.

    2. Remove the 3 gaskets from the No. 1 oil cooler bracket.

  35. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A012HEO

      Remove the No. 1 cylinder block insulator from the cylinder block sub-assembly.

  36. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A012I9U

      Remove the 2 bolts and No. 2 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 2 water by-pass pipe.

  37. REMOVE NO. 4 WATER BY-PASS HOSE

    A012JH8

    Slide the 2 clips and remove the No. 4 water by-pass hose.

  38. REMOVE WATER INLET HOUSING


    1. A012IZP

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  39. REMOVE FUEL HOSE PROTECTOR

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  40. REMOVE FUEL TUBE SUB-ASSEMBLY

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  41. REMOVE NO. 3 FUEL HOSE

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  42. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A012MKJC01
      A012L0C Check Valve

      Remove the check valve and gasket.

    2. Remove the bolt and No. 2 nozzle leakage pipe.

  43. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

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  44. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A012G8O

      Remove the 4 bolts, 4 washers and 4 No. 1 nozzle holder clamps.

  45. REMOVE INJECTOR ASSEMBLY

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  46. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  47. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A012KYJ

      Disengage the 8 clamps and remove the 2 vacuum transmitting hose assemblies.

  48. REMOVE NO. 1 WIRE HARNESS CLAMP BRACKET


    1. A012HTC

      Remove the bolt and No. 1 wire harness clamp bracket.

  49. REMOVE VENTILATION HOSE

    A012LIX

    1. Slide the clip and remove the ventilation hose.

  50. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly.

    2. A012GWPC01
      A012L0C Nozzle Holder Clamp Seat
      A012HN3 Nut

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

    3. A012L33

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  51. REMOVE OIL PAN SUB-ASSEMBLY


    1. A012FRGC01
      A012L0C Nut

      Remove the 18 bolts and 2 nuts.

    2. A012GTI

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

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing chain cover sub-assembly.

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

  52. REMOVE OIL FILTER ELEMENT

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  53. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY

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  54. REMOVE OIL FILTER BRACKET


    1. A012KPV

      Remove the 4 bolts and oil filter bracket.

    2. A012G5L

      Remove the gasket from the oil filter bracket.

  55. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. A012M3I

      Using a 5 mm hexagon wrench, remove the bolt and oil check valve sub-assembly from the oil filter bracket.

  56. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A012HQUC05
      *a Ball

      Push the ball of the oil check valve sub-assembly to check if it is stuck.

      If the check valve is stuck, replace the oil check valve sub-assembly.

  57. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A012K8C

      Remove the 3 bolts and oil strainer sub-assembly.

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

  58. REMOVE CAMSHAFT POSITION SENSOR

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  59. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A012GXL

      Remove the clip, bolt and disconnect the crankshaft position sensor wire harness.

  60. REMOVE ENGINE WATER PUMP ASSEMBLY

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  61. REMOVE CRANKSHAFT PULLEY

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  62. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A012ICQC01
      A012L0C Bolt and Seal Washer

      Remove the 13 bolts and seal washer.

    2. A012MRPC02
      *a Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing, cylinder block sub-assembly and stiffening crankcase with a screwdriver as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing, cylinder block sub-assembly, stiffening crankcase and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A012FKVC01
      *1 Gasket
      *2 O-Ring

      Remove the gasket and O-ring from the timing chain cover sub-assembly.

  63. REMOVE STRAIGHT SCREW PLUG

    Tech Tips

    Perform this procedure only when replacement of the straight screw plug.


    1. A012I7P

      Using a 10 mm socket hexagon wrench, remove the straight screw plug and gasket.

  64. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A012KDPC01
      *a Protective Tape

      Place the timing chain cover sub-assembly on wooden blocks.

    2. Using a screwdriver, pry out the front crankshaft oil seal.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  65. REPLACE STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A012FI8C01
      *1 34 mm (1.34 in.)
      *2 25 mm (0.984 in.)
      *3 9.0 mm (0.354 in.)

      Using an E6 "TORX" wrench, replace the 3 stud bolts.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }