OIL PUMP REMOVAL

Note

Do not remove the oil pump or oil pump relief valve from the timing chain cover sub-assembly.


  1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

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  2. REMOVE IGNITION COIL ASSEMBLY


    1. B000JPZ

      Disconnect the 4 ignition coil assembly connectors.

    2. Remove the 4 bolts and 4 ignition coil assemblies from the cylinder head cover sub-assembly.

      Note

      If an ignition coil assembly has been struck or dropped, replace it.

      Tech Tips

      Arrange the removed parts in the correct order.

  3. DISCONNECT NO. 2 VENTILATION HOSE


    1. B000N7Z

      Slide the clip and disconnect the No. 2 ventilation hose from the PCV valve (ventilation valve sub-assembly).

  4. REMOVE FUEL PUMP PROTECTOR


    1. B000MEM

      Remove the 2 bolts and fuel pump protector from the cylinder head cover sub-assembly.

  5. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. Disconnect the fuel tube sub-assembly from the No. 1 fuel pipe.


      1. B000MGZE04
        Text in Illustration
        *a Fuel Tube Connector Cover
        B000K70 Pull off

        Pull off the fuel tube connector cover.

      2. B000HHQE01
        Text in Illustration
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        B000K70 Pinch
        B000IB9 Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).


        • Do not bend, twist, pinch or kink the nylon tube.

      4. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  6. REMOVE NO. 1 FUEL PIPE


    1. B000HE3

      Remove the No. 1 fuel pipe and gasket from the fuel pump with seal sub-assembly.

  7. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B000I5W

      Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

    2. B000LKK

      Loosen the 2 bolts of the fuel pump with seal sub- assembly.

    3. Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly and fuel pump with seal sub- assembly.

  8. REMOVE FUEL PUMP WITH SEAL SUB-ASSEMBLY


    1. B000MWH

      Disconnect the fuel pump with seal sub-assembly connector.

    2. Remove the 2 bolts and fuel pump with seal sub- assembly from the cylinder head cover sub- assembly.

    3. B000JICE01
      Text in Illustration
      *1 Fuel Pump with Seal Sub-assembly
      *2 Fuel Pump Insulator
      *3 Fuel Pump Lifter Assembly
      *4 Fuel Pump Lifter Guide

      Remove the fuel pump lifter guide, fuel pump lifter assembly and fuel pump insulator from the fuel pump with seal sub-assembly.

    4. B000J7L

      Remove the O-ring from the fuel pump sub- assembly.

    5. B000N9UE01
      Text in Illustration
      *1 Fuel Pump Spacer Gasket
      *2 O-ring

      Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.

    6. Remove the 2 O-rings from the No. 4 camshaft bearing cap.

  9. REMOVE EGR VALVE BRACKET


    1. B000KUB

      Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.

    2. B000KP2

      Remove the 4 bolts and 2 EGR valve brackets.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000HPN

      Remove the 17 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Bolt with Seal Washer
    2. B000JJVE01
      Text in Illustration
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *a Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

    3. Remove the gasket from the No. 2 camshaft bearing cap.

  11. REMOVE CRANKSHAFT POSITION SENSOR

    B000JIE

    1. Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  12. REMOVE CRANKSHAFT PULLEY


    1. B000MO0E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. B000N3YE04
      Text in Illustration
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

      Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley and crankshaft pulley set bolt.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05011 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  13. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY


    1. B000HM8

      Disconnect the camshaft timing oil control solenoid assembly connector.

    2. Remove the 2 bolts and camshaft timing oil control solenoid assembly from the timing chain cover sub-assembly.

      Note

      If the camshaft timing oil control solenoid assembly has been struck or dropped, replace it.

    3. B000JQG

      Remove the O-ring from the camshaft timing oil control solenoid assembly.

      Note


      • If the O-ring comes off in the timing chain cover sub-assembly, make sure to remove it.

      • Do not drop the O-ring into the timing chain cover sub-assembly.

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B000N8Q

      Remove the dust cover from the V-ribbed belt tensioner assembly.

    2. B000HJ5

      Remove the bolt and V-ribbed belt tensioner assembly from the water inlet housing.

  15. REMOVE ENGINE MOUNTING BRACKET RH


    1. B000HZQ

      Remove the 5 bolts and engine mounting bracket RH.

  16. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B000IDS

      Remove the 17 bolts and 2 nuts.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

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

      B000MOSE01
      Text in Illustration
      *a Protective Tape - -

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. B000JJSE01
      Text in Illustration
      *1 Oil Pump Gasket
      *2 Oil Hole Cover Gasket

      Remove the 2 oil pump gaskets and oil hole cover gasket from the stiffening crankcase assembly.

  17. REMOVE TIMING CHAIN COVER OIL SEAL


    1. B000JGYE05
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pry out the timing chain cover oil seal.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.