OIL PUMP (w/o 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 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.

      A00JVX9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  6. REMOVE ENGINE ASSEMBLY


    1. Remove the engine Click here.

  7. INSTALL ENGINE TO ENGINE STAND

  8. REMOVE GENERATOR ASSEMBLY


    1. A00K0CA

      Remove the 2 bolts and generator.

  9. REMOVE GENERATOR BRACKET


    1. A00JWMI

      Remove the bolt and generator bracket.

  10. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00K11Y

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

  11. REMOVE VENTILATION PIPE


    1. A00O8AJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00OB7F

      Remove the 2 bolts and engine oil level dipstick guide.

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

  13. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00JXED

      Remove the 4 bolts and No. 2 cylinder head cover.

  14. REMOVE TIMING GEAR COVER INSULATOR


    1. A00JUUI

      Remove the bolt and gear cover insulator.

  15. REMOVE VACUUM PUMP ASSEMBLY


    1. A00JWM7E01

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

  16. REMOVE VANE PUMP ASSEMBLY


    1. A00JX1D

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

  17. REMOVE CAMSHAFT POSITION SENSOR


    1. A00JVQX

      Remove the bolt and camshaft position sensor.

  18. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00JUJI

      Detach the clamp and remove the bolt and crankshaft position sensor.

  19. REMOVE TIMING BELT


    1. Remove the timing belt Click here.

  20. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  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 ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve Click here.

  23. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A00OA28

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  24. REMOVE INJECTION PIPE (w/o EGR System)

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A00XH0D

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A00XH1Z

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A00XJETE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  25. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A00O30T

      Remove the 3 bolts and air connector stay.

  26. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A00O7OP

      Disconnect the throttle position sensor connector.

    2. A00O5VW

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  27. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A00O5P2

        w/o EGR System:

        Disconnect the connector.

      2. A00O70W

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A00O5WE

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A00O3VL

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00OB6W

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A00OAHN

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A00O4FYE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A00O5B8

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  28. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A00JZ4Y

      Loosen the union nuts and remove the fuel inlet pipe.

  29. REMOVE SUPPLY PUMP ASSEMBLY


    1. A00K1VXE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    3. A00JWI4E05

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    4. A00K1NZ

      Loosen the 2 nuts.

    5. A00JZAIE03

      Using SST, disconnect the supply pump from the injection gear.

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

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. Remove the 2 nuts and supply pump.

      Note


      • Do not hold or carry the fuel supply pump by holding the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring.

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


    1. A00JWRB

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

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


    1. A00JZ70

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

  32. REMOVE NOZZLE HOLDER SEAL


    1. A00XD84E01

      Using a small screwdriver, remove the 4 holder seals by prying between each holder seal and the cutout part of the cylinder head cover.

  33. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A00XINNE01

      Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.

    2. A00XCKH

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  34. REMOVE INJECTOR ASSEMBLY


    1. A00XEY5E04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A00XGHLE01

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

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  35. REMOVE CAMSHAFT TIMING PULLEY


    1. A00XEISE01

      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.

  36. REMOVE NO. 2 TIMING BELT COVER


    1. A00XDLI

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

  37. REMOVE WATER PUMP ASSEMBLY


    1. A00JUIH

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

  38. 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. A00K16QE01

      Remove the 14 bolts and 2 nuts.

    2. A00JZ91E01

      Pry the gear cover at the locations shown in the illustration, and remove the gear cover together with the injection gear.

      Note

      Be careful not to drop the injection gear.

    3. A00JV44

      Remove the O-ring from the timing gear case.

  39. 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.

  40. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A00JZDQE01

      Remove the No. 1 crankshaft position sensor plate.

  41. REMOVE CRANKSHAFT TIMING GEAR


    1. A00JXF2E01

      Using SST, remove the crankshaft timing gear.

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

  42. REMOVE IDLE GEAR THRUST PLATE


    1. A00JV12E01

      Remove the 2 bolts and thrust plate.

  43. REMOVE NO. 1 IDLE GEAR


    1. A00K1MNE01

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

  44. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A00K16NE01

      Remove the idle gear shaft.

  45. 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.

  46. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00K0EM

      Remove the 2 nuts, oil strainer and gasket.

  47. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00JW3T

      Remove the 22 bolts and 2 nuts.

    2. A00JZWIE01
      Text in Illustration
      *A LH Side
      *B RH Side
      *1 Pry

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A00JXGA

      Remove the gasket.

  48. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A00JU79E01

      Remove the union bolt and 8 bolts.

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

    3. Remove the 2 O-rings.