OIL PUMP REMOVAL

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.


  1. REMOVE ENGINE ASSEMBLY


    1. Remove the engine assembly Click here.

  2. DISCONNECT ENGINE WIRE


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

  3. REMOVE GENERATOR ASSEMBLY


    1. A00E7HT

      Remove the 3 bolts and generator.

  4. REMOVE VACUUM PUMP ASSEMBLY


    1. A00EAYO

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump.

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

  5. REMOVE IDLER PULLEY COVER PLATE


    1. A00E849E01
      Text in Illustration
      *1 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. A00E9H0

      Remove the bolt and No. 1 idler pulley.

  7. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A00E83ZE01
      Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley.

  8. REMOVE NO. 4 WATER BY-PASS PIPE


    1. A00E6QV

      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. A00E7YE

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

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A00EAR2

      Remove the 3 bolts and V-ribbed belt tensioner.

      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. A00EB5RE01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Disconnect the No. 6 and No. 7 water by-pass hoses.

    2. A00E8R7

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

  12. REMOVE NO. 7 WATER BY-PASS HOSE

    A003C0A

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A003C1D

  14. REMOVE EGR VALVE BRACKET


    1. A00EAGF

      Remove the 3 bolts and 2 EGR valve brackets.

  15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A003BVE

      Disconnect the electric EGR control valve connector.

    2. A003CDBE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts and No. 2 EGR pipe.

    3. Remove the 2 gaskets.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003AHE

      Remove the electric EGR control valve and gasket.

  17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00E7VT

      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

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  19. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  20. REMOVE NO. 4 FUEL HOSE

    A00E7JG

  21. REMOVE COMMON RAIL ASSEMBLY


    1. A00E871

      Remove the 2 bolts and common rail.

  22. REMOVE INTAKE MANIFOLD INSULATOR


    1. A003CC9

      Remove the intake manifold insulator from the intake manifold.

  23. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A00EAXX

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  24. REMOVE NO. 1 GAS FILTER


    1. A003BBJ

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  25. REMOVE GAS FILTER BRACKET


    1. A003AWW

      Remove the 2 bolts and gas filter bracket.

  26. REMOVE ENGINE COVER BRACKET


    1. A003EJ9

      Remove the bolt and engine cover bracket.

  27. REMOVE NO. 2 INTAKE MANIFOLD


    1. A003DE3

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  28. REMOVE INTAKE MANIFOLD


    1. A003DELE01
      Text in Illustration
      *1 Nut

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

  29. REMOVE WATER BY-PASS HOSE

    A003CG4

  30. REMOVE OIL COOLER ASSEMBLY


    1. A003DKC

      Remove the 5 bolts and oil cooler.

    2. Remove the 3 O-rings from the oil cooler bracket.

  31. REMOVE NO. 6 WATER BY-PASS HOSE

    A00EB4I

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    A00E8GW

  33. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A00E88F

      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. A00EAWR

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

  35. REMOVE NO. 1 OIL COOLER BRACKET


    1. A00E9L8E01
      Text in Illustration
      *1 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. A00E6YU

      Remove the No. 1 cylinder block insulator from the cylinder block.

  37. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A00EBC9

      Remove the 2 bolts and No. 2 water by-pass pipe from the water inlet housing.

  38. REMOVE NO. 4 WATER BY-PASS HOSE

    A00E7QM

  39. REMOVE WATER INLET HOUSING


    1. A00E79K

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  40. REMOVE FUEL HOSE PROTECTOR


    1. A003BGR

      Remove the bolt and fuel hose protector.

  41. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A003CV6

      Disconnect the exhaust fuel addition injector connector.

    2. A003BVV

      Turn the retainer as shown in the illustration.

    3. A003BLP

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A003D04E01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    5. Remove the union bolt, gasket and fuel tube.

  42. REMOVE NO. 3 FUEL HOSE

    A00E9GI

  43. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A00EB9OE01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

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

  44. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A003D2W

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  45. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A00E6MT

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  46. REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector.

      Note

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.

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


    1. A00EAA9

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and No. 1 vacuum transmitting pipe.

  48. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A00EA6B

      Disconnect the 2 vacuum hoses.

    2. Remove the 5 bolts and vacuum switching valve bracket.

  49. REMOVE VENTILATION HOSE

    A00E9U5

  50. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  51. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00EAWYE01
      Text in Illustration
      *1 Bolt
      *2 Nozzle Holder Clamp Seat
      *3 Nut

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

    2. A00E9F2E01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket

      Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover.

  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00EARPE01
      Text in Illustration
      *1 Nut

      Remove the 18 bolts and 2 nuts.

    2. A00E8I4E06

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note


      • Do not use the oil pan seal cutter for the timing chain cover side.

      • Be careful not to damage the contact surfaces of the oil pan.

  53. REMOVE OIL FILTER ELEMENT


    1. A00E89A

      Remove the oil filter drain plug.

    2. Remove the O-ring from the oil filter drain plug and install it to an oil filter drain pipe.

    3. A00E9WUE01
      Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Drain Pipe

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

    4. Remove the oil filter drain pipe.

    5. Apply a light coat of engine oil to a new O-ring and install it to the oil filter drain plug.

    6. A00E89A

      Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    7. A00E99NE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    8. A00E8TJE01
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Be sure to remove the cap O-ring by hand without using any tools to prevent damage to the cap O-ring groove.

  54. REMOVE OIL FILTER BRACKET


    1. A00E73E

      Remove the 4 bolts and oil filter bracket.

    2. A00E8O7

      Remove the gasket from the oil filter bracket.

  55. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00EAJ9

      Remove the 3 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  56. REMOVE CAMSHAFT POSITION SENSOR


    1. A00E8ZX

      Remove the bolt and sensor.

  57. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A00E89E

      Using a clip remover, remove the clip.

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

  58. REMOVE WATER PUMP ASSEMBLY


    1. A003DRL

      Remove the 7 bolts, water pump and gasket.

  59. REMOVE CRANKSHAFT PULLEY


    1. Set the No. 1 piston to TDC/compression.


      1. A00OVCCE01
        Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark

        Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.

    2. A00OSC1E01
      Text in Illustration
      *1 Matchmark
      *2 Timing Mark

      Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/compression).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tech Tips

      The timing chain has 2 yellow-colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A00OT6SE01

      Turn the crankshaft by approximately 90° in the engine revolution direction from the point where the No. 1 piston is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

    5. A00OQDQE01

      Using SST, remove the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    6. A00OS3NE01

      Using SST, remove the crankshaft pulley.

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

  60. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00E6XLE01
      Text in Illustration
      *1 Bolt and Seal Washer

      Remove the 13 bolts and seal washer.

    2. A00EA0P

      Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver 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 head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

    3. A00E6MXE01
      Text in Illustration
      *1 Gasket
      *2 O-Ring

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

  61. REMOVE STRAIGHT SCREW PLUG


    1. A00EA8A

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

  62. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A00E9VS

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Do not damage the surface of the oil seal press fit hole.

  63. REPLACE STUD BOLT

    Tech Tips

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


    1. A00E6J7E01

      Using an E6 "TORX" wrench, replace the 3 stud bolts.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }