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. REMOVE ENGINE ASSEMBLY

    Click here

  2. DISCONNECT ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine, remove the bracket bolts and disconnect the engine wire from the engine.

  3. REMOVE GENERATOR ASSEMBLY

    Click here

  4. REMOVE VACUUM PUMP ASSEMBLY


    1. A01GAEV

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump assembly.

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

  5. REMOVE IDLER PULLEY COVER PLATE


    1. A01GCGRC01
      *1 Protective Tape

      Using a screwdriver, remove the idler pulley cover plate.

      Tech Tips

      Tape the screwdriver tip before use.

  6. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01GBGF

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

  7. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01GDEUC03
      *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.

  8. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A01GD9F

      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.

  9. REMOVE ENGINE MOUNTING BRACKET


    1. A01GC02

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

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01GCWL

      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.

  11. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01GCSEC02
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Slide the 2 clamps and disconnect the No. 6 water by-pass hose and No. 7 water by-pass hose from the diesel throttle body assembly.

    2. A01GCA1

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

  12. REMOVE NO. 7 WATER BY-PASS HOSE

    Click here

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  14. REMOVE EGR VALVE BRACKET


    1. A01GCFX

      Remove the 3 bolts and EGR valve bracket.

  15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01GCCF

      Remove the 2 bolts and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  18. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  19. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  20. REMOVE NO. 4 FUEL HOSE


    1. A01GBJ7

      Slide the 2 clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe and common rail assembly.

  21. REMOVE COMMON RAIL ASSEMBLY


    1. A01GCXX

      Remove the 2 bolts and common rail assembly.

  22. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  23. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  24. REMOVE NO. 1 GAS FILTER

    Click here

  25. REMOVE GAS FILTER BRACKET

    Click here

  26. REMOVE ENGINE COVER BRACKET

    Click here

  27. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

  28. REMOVE INTAKE MANIFOLD

    Click here

  29. REMOVE WATER BY-PASS HOSE

    Click here

  30. REMOVE OIL COOLER ASSEMBLY

    Click here

  31. REMOVE NO. 6 WATER BY-PASS HOSE


    1. A01G9XB

      Slide the clamp and remove the No. 6 water by-pass hose from the water outlet.

  32. REMOVE NO. 8 WATER BY-PASS HOSE


    1. A01GD6X

      Slide the clamp and remove the No. 8 water by-pass hose from the No. 3 water by-pass pipe.

  33. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01GCL4

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

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

  34. REMOVE NO. 1 TURBO OIL PIPE


    1. A01GCGF

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

  35. REMOVE NO. 1 OIL COOLER BRACKET


    1. A01G9YJC01
      A01GBFL Nut

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

    2. Remove the 3 O-rings from the No. 1 oil cooler bracket.

  36. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A01GDEL

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

  37. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01GBHS

      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.

  38. REMOVE NO. 4 WATER BY-PASS HOSE


    1. A01GCUY

      Slide the 2 clamps and disconnect the No. 4 water by-pass hose from the elbow and water inlet housing.

  39. REMOVE WATER INLET HOUSING


    1. A01GCNX

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  40. REMOVE NO. 2 FUEL PIPE (for CCo)

    Click here

  41. REMOVE FUEL HOSE PROTECTOR (for DPF)

    Click here

  42. REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)

    Click here

  43. REMOVE NO. 3 FUEL HOSE


    1. A01GCAT

      Slide the 2 clamps and remove the No. 3 fuel hose from the No. 2 nozzle leakage pipe and fuel supply pump assembly.

  44. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01GD5SC02
      A01GBFL Check Valve

      Remove the check valve and gasket.

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

  45. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  46. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01GBZY

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

  47. REMOVE INJECTOR ASSEMBLY

    Click here

  48. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  49. REMOVE VACUUM REGULATING VALVE ASSEMBLY

    Click here

  50. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01GD4I

      Detach the 10 clamps and remove the 2 vacuum transmitting hoses.

  51. REMOVE PCV HOSE


    1. A01GC4T

      Slide the clamp and remove the PCV hose from the cylinder head cover sub-assembly.

  52. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  53. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01GD8JC02
      A01GAQ1 Bolt
      A01GBFL Nozzle Holder Clamp Seat
      A01GAGP Nut

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

    2. A01GAB6

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

  54. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01GAXPC01
      A01GBFL Nut

      Remove the 18 bolts and 2 nuts.

    2. A01GB6D

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

      Note


      • Do not use the oil pan seal cutter for the area between the No. 2 oil pan sub-assembly and timing chain cover sub-assembly.

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

  55. REMOVE OIL FILTER ELEMENT

    Click here

  56. REMOVE OIL FILTER BRACKET


    1. A01GD6I

      Remove the 4 bolts and oil filter bracket.

    2. A01GAW1

      Remove the gasket from the oil filter bracket.

  57. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01GCUE

      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

    Click here

  59. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A01GC59

      Using a clip remover, remove the clip.

    2. Remove the bolt and disconnect the crankshaft position sensor wire harness.

  60. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  61. SET NO. 1 PISTON TO TDC / COMPRESSION

    Click here

  62. REMOVE CRANKSHAFT PULLEY

    Click here

  63. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01GBRAC01
      A01GBFL Bolt and Seal Washer

      Remove the 13 bolts and seal washer.

    2. A01GC2IC01
      *1 Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, 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, cylinder block sub-assembly, stiffening crankcase and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01GAURC01
      *1 Gasket
      *2 O-Ring

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

  64. REMOVE STRAIGHT SCREW PLUG

    Tech Tips

    It is not necessary to replace the straight screw plug if there is no damage to the straight screw plug and no sign of oil leaks.


    1. A01GBGA

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

  65. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01G9VQC01
      *1 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 front crankshaft oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  66. REMOVE STUD BOLT

    Tech Tips

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