OIL PUMP REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of engine assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

  • Clear Crank Time Compensation Data

 Engine starting
Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

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. 2 HOSE TO HOSE TUBE

    Click here

  3. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  4. REMOVE ENGINE WIRE

  5. REMOVE INTERCOOLER AIR TUBE

    Click here

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  7. REMOVE NO. 2 WATER BY-PASS PIPE

    Click here

  8. REMOVE ENGINE COVER BRACKET

    Click here

  9. REMOVE GAS FILTER

    Click here

  10. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  11. REMOVE EGR VALVE BRACKET

    Click here

  12. REMOVE NO. 2 EGR PIPE

    Click here

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


  14. REMOVE CONNECTING WIRE

    Click here

  15. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE VACUUM CONTROL VALVE SET (w/ EGR Cooler)

    Click here

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

    Click here

  18. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Cooler)

    Click here

  19. REMOVE EGR VALVE ADAPTER WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)

    Click here

  20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  21. REMOVE NO. 2 FUEL PIPE

    Click here

  22. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  23. REMOVE MANIFOLD STAY

    Click here

  24. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  25. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  26. REMOVE NO. 2 FUEL HOSE

    Click here

  27. REMOVE NO. 1 FUEL HOSE

    Click here

  28. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ Pressurized Fuel Filter)

    Click here

  29. REMOVE NO. 3 FUEL PIPE (w/ Pressurized Fuel Filter)

    Click here

  30. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  31. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  32. REMOVE INTAKE MANIFOLD

    Click here

  33. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  34. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  35. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

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

    Click here

  37. REMOVE HOSE BRACKET

    Click here

  38. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  39. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


  40. REMOVE NO. 1 TURBO INSULATOR


  41. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY


  42. REMOVE EXHAUST PIPE SUPPORT STAY


  43. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  44. INSTALL TURBINE OUTLET ELBOW (w/o EGR Cooler)

    Click here

  45. REMOVE PCV HOSE

    Click here

  46. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  47. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  48. DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  49. REMOVE TURBOCHARGER STAY

    Click here

  50. REMOVE TURBO OIL OUTLET PIPE

    Click here

  51. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  52. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

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

    Click here

  54. REMOVE WATER OUTLET SUB-ASSEMBLY

    Click here

  55. REMOVE WATER INLET

    Click here

  56. REMOVE THERMOSTAT

    Click here

  57. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B003SBW

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

  58. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B003KQR

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

  59. REMOVE CRANKSHAFT PULLEY

    Click here

  60. REMOVE NO. 1 ENGINE HANGER

    Click here

  61. REMOVE GENERATOR BRACKET SUB-ASSEMBLY

    Click here

  62. REMOVE INJECTOR ASSEMBLY

    Click here

  63. REMOVE NOZZLE HOLDER GASKET

    Click here

  64. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  65. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B003RTRC01
      B003R2S Bolt
      B003LF2 Nut
      B003QHB Nozzle Holder Clamp Seat

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

    2. B003JNEC01
      *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.

  66. REMOVE OIL PAN COVER SILENCER


    1. B003MQV

      Remove the 5 bolts and oil pan cover silencer from the oil pan sub-assembly.

  67. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  68. REMOVE OIL PAN SUB-ASSEMBLY


    1. B003O2GC01
      B003R2S Bolt
      B003LF2 Nut

      Remove the 23 bolts and 2 nuts.

    2. B003M4A

      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 cylinder block sub-assembly and oil pan sub-assembly.

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

  69. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  70. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  71. REMOVE TIMING CHAIN COVER PLATE

    Click here

  72. REMOVE SUPPLY PUMP ASSEMBLY

    Click here

  73. INSTALL INJECTION PUMP INSULATOR

    Click here

  74. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B003JZE

      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.

      B003N2EC01
      *a Protective Tape - -

      Note

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

    3. B003OIT

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

  75. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B003RP1C01
      *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.

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


    1. B003M4E

      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.

  77. REMOVE OIL PUMP DRIVE GEAR


    1. B003J71

      Remove the oil pump drive gear from the crankshaft.

  78. REMOVE TIMING CHAIN GUIDE

    Click here

  79. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  80. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    Click here

  81. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  82. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

    Click here

  83. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  84. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    Click here

  85. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

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

    Click here

  87. REMOVE CAMSHAFT TIMING SPROCKET

    Click here

  88. REMOVE TIMING CHAIN CASE ASSEMBLY


    1. B003LKH

      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.

      B003RD9C01
      *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. B003JGU

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