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OIL PUMP INSTALLATION

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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, No. 3 injection pipe sub-assembly, No. 4 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

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

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PROCEDURE


  1. Click here

    INSTALL TIMING GEAR CASE ASSEMBLY

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  2. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY

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  3. Click here

    INSTALL OIL PAN SUB-ASSEMBLY

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  4. Click here

    INSTALL FUEL SUPPLY PUMP ASSEMBLY

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  5. Click here

    INSTALL INJECTION GEAR

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  6. Click here

    INSTALL CRANKSHAFT TIMING GEAR

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  7. Click here

    INSTALL NO. 1 IDLE GEAR SHAFT

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  8. Click here

    INSTALL NO. 1 IDLE GEAR

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  9. Click here

    INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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  10. Click here

    INSTALL TIMING GEAR COVER

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  11. Click here

    INSTALL CRANKSHAFT PULLEY SUB-ASSEMBLY

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  12. Click here

    INSTALL PUMP DRIVE SHAFT PULLEY


    1. Install a new O-ring to the fuel supply pump assembly.

    2. Temporarily install the fuel supply pump assembly with the nut.

    3. B00259KC01
      *a Hold
      B0068HS Turn

      Using SST, hold the crankshaft pulley and tighten the nut.

      09213-58014 91551-80840
      09330-00021
      63.7 N*m 650 kgf*cm 47 ft.*lbf

    4. Install the No. 2 camshaft timing pulley flange and pump drive shaft pulley to the timing gear cover with the 4 bolts.

      31 N*m 316 kgf*cm 23 ft.*lbf
    5. B00289Z

      Using a dial indicator, check the thrust clearance of the pump drive shaft while moving the pump drive shaft pulley back and forth.

      Standard thrust clearance (reference)
      0.15 to 0.55 mm (0.00591 to 0.0217 in.)
      Tip:

      If there is no clearance, remove and reinstall the fuel supply pump assembly and pump drive shaft pulley. Then repeat the step above.

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    INSTALL CRANKSHAFT POSITION SENSOR

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  14. Click here

    INSTALL CAMSHAFT POSITION SENSOR

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  15. Click here

    INSTALL VANE PUMP ASSEMBLY

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  16. Click here

    INSTALL VACUUM PUMP ASSEMBLY

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  17. Click here

    INSTALL ENGINE WATER PUMP ASSEMBLY

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  18. Click here

    INSTALL NO. 2 TIMING BELT COVER

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  19. Click here

    INSTALL CAMSHAFT TIMING PULLEY

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  20. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  21. Click here

    INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  22. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  23. Click here

    INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

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  24. Click here

    INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  25. Click here

    INSTALL MANIFOLD STAY

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  26. Click here

    INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

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  27. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  28. Click here

    INSTALL GENERATOR BRACKET

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  29. Click here

    INSTALL GENERATOR ASSEMBLY

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  30. Click here

    INSTALL NO. 2 IDLE PULLEY ASSEMBLY

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  31. Click here

    INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

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  32. Click here

    INSTALL TIMING BELT

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  33. Click here

    INSTALL NO. 1 TIMING BELT COVER

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  34. Click here

    INSTALL ENGINE ASSEMBLY

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  35. Click here

    ADD ENGINE OIL

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  36. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  37. Click here

    BLEED AIR FROM FUEL SYSTEM

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  38. Click here

    ADD ENGINE COOLANT

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  39. Click here

    BLEED AIR FROM POWER STEERING SYSTEM

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  40. Click here

    INSPECT FOR POWER STEERING FLUID LEVEL

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  41. Click here

    PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes.

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    2. Perform pilot quantity learning.

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  42. Click here

    INSPECT FOR OIL LEAK

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  43. Click here

    INSPECT FOR COOLANT LEAK

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  44. Click here

    INSPECT FOR EXHAUST GAS LEAK

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  45. Click here

    INSPECT FOR FUEL LEAK

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  46. Click here

    INSPECT ENGINE OIL LEVEL

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