OIL PUMP (w/ DPF) REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

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

  2. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  3. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  5. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A00JWDE

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A00JTSGE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  6. REMOVE ENGINE ASSEMBLY

    Click here

  7. INSTALL ENGINE TO ENGINE STAND

  8. REMOVE TIMING BELT

    Click here

  9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  10. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  11. REMOVE INJECTOR ASSEMBLY

    Click here

  12. REMOVE GENERATOR ASSEMBLY


    1. A00JWXP

      Remove the 2 bolts and generator.

  13. REMOVE GENERATOR BRACKET


    1. A00JVLM

      Remove the bolt and generator bracket.

  14. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A00JUTJ

      Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  15. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00JXLV

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  16. REMOVE VACUUM PUMP ASSEMBLY


    1. A00JWM7E01

      Remove the 2 nuts, vacuum pump and 2 O-rings.

  17. REMOVE VANE PUMP ASSEMBLY


    1. A00JX1D

      Remove the 2 nuts, vane pump and O-ring.

  18. REMOVE CAMSHAFT POSITION SENSOR


    1. A00JVQX

      Remove the bolt and camshaft position sensor.

  19. REMOVE CRANKSHAFT POSITION SENSOR


    1. Disconnect the crankshaft position sensor connector.

    2. A00JYTWE01

      Remove the clamp labeled A in the illustration.

      Note


      • Make sure that no portion of the clamp labeled A remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

      • Do not reuse the clamp labeled A.

    3. Detach the 3 wire harness clamps and remove the bolt and crankshaft position sensor.

  20. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. A00JYX1

      Remove the bolt and oil pressure switching valve.

  21. REMOVE CRANKSHAFT PULLEY


    1. A00JZE1E01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A00JYY4E01

      Using SST, remove the pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  22. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A00JZ1E

      Remove the bolt, nut and No. 1 vacuum transmitting pipe.

  23. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. A00JZ70

      Remove the 4 bolts and No. 1 oil pan cover.

  24. REMOVE CAMSHAFT TIMING PULLEY


    1. A00O9HVE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  25. REMOVE NO. 2 TIMING BELT COVER


    1. A00O7OS

      Remove the 4 bolts, nut and No. 2 timing belt cover.

  26. REMOVE WATER PUMP ASSEMBLY


    1. A00JUIH

      Remove the 5 bolts, 2 nuts, water pump and gasket.

  27. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump.


    1. A00JXJS

      Remove the 14 bolts and 2 nuts.

    2. A00JWMV

      Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

      Note

      Be careful not to drop the injection gear.

    3. A00JZ5L

      Remove the 3 O-rings from the timing gear case.

  28. REMOVE INJECTION GEAR


    1. A00JZS1

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.

    2. A00JVGT

      Remove the injection gear.

  29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00JY21

      Remove the No. 1 crankshaft position sensor plate.

  30. REMOVE CRANKSHAFT TIMING GEAR


    1. A00JXF2E01

      Using SST, remove the crankshaft timing gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  31. REMOVE IDLE GEAR THRUST PLATE


    1. A00JUAU

      Remove the 2 bolts and idle gear thrust plate.

  32. REMOVE NO. 1 IDLE GEAR


    1. A00JZ8S

      Remove the No. 1 idle gear together with the No. 2 idle sub gear.

  33. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A00K1O0

      Remove the No. 1 idle gear shaft.

  34. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00JVEN

      Remove the 11 bolts and 2 nuts.

    2. A00K0U4

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

  35. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00K0EM

      Remove the 2 nuts, oil strainer and gasket.

  36. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00JW3T

      Remove the 22 bolts and 2 nuts.

    2. A00JZWIE02
      Text in Illustration
      *A LH Side
      *B RH Side
      *a Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A00JXGA

      Remove the gasket.

  37. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A00JVR6

      Remove the union bolt and 8 bolts.

    2. A00JZII

      Pry the timing gear case at the location shown in the illustration and remove the gear case and gasket.

    3. A00K1GQE03

      Remove the 2 O-rings.