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

    Click here

  2. DISCONNECT ENGINE WIRE


    1. Disconnect the connectors and detach the 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. Remove the terminal cap.

    2. A00OU1K

      Disconnect the generator connector and detach the clamp.

    3. Remove the nut and disconnect the generator wire from terminal B.

    4. Remove the bolt and wire harness clamp bracket.

    5. A00OVE9

      Remove the 3 bolts and generator.

  4. REMOVE VACUUM PUMP ASSEMBLY


    1. A00OR02

      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. A00ORCGE01
      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. A00ORP0

      Remove the bolt and No. 1 idler pulley.

  7. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A00ORZEE01
      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. A00ORNB

      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. A00OQMX

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

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A00OTNN

      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. A00OQTYE01
      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. A00OSP8

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

  12. REMOVE NO. 7 WATER BY-PASS HOSE

    A00OSGC

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A00OVYQ

  14. REMOVE EGR VALVE BRACKET


    1. A00ORPA

      Remove the 3 bolts and 2 EGR valve brackets.

  15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A00OQKV

      Disconnect the electric EGR control valve connector.

    2. A00OSQME01
      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. A00OW3B

      Remove the electric EGR control valve and gasket.

  17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A00OQW3

      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. A00OT1T

      Remove the nut and 2 No. 2 injection pipe 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. A00OQOI

      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

    A00OSE6

  21. REMOVE COMMON RAIL ASSEMBLY


    1. A00OUME

      Remove the 2 bolts and common rail.

  22. REMOVE INTAKE MANIFOLD INSULATOR


    1. A00OSN4

      Remove the intake manifold insulator from the intake manifold.

  23. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A00OU6H

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  24. REMOVE NO. 1 GAS FILTER


    1. A00OUQK

      Disconnect the vacuum hose.

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

  25. REMOVE GAS FILTER BRACKET


    1. A00OVKD

      Remove the 2 bolts and gas filter bracket.

  26. REMOVE ENGINE COVER BRACKET


    1. A00OURK

      Remove the bolt and engine cover bracket.

  27. REMOVE NO. 2 INTAKE MANIFOLD


    1. A00OUSS

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

  28. REMOVE INTAKE MANIFOLD


    1. A00OVS2E01
      Text in Illustration
      *1 Nut

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

  29. REMOVE WATER BY-PASS HOSE

    A00ORYW

  30. REMOVE OIL COOLER ASSEMBLY


    1. A00OVUH

      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

    A00OUJ2

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    A00OR5P

  33. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A00OR61

      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. A00OSS6

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

  35. REMOVE NO. 1 OIL COOLER BRACKET


    1. A00OV34

      Remove the 6 bolts, nut and No. 1 oil cooler bracket.

      Text in Illustration
      A00OVAR Nut

    2. Remove the 3 O-rings from the No. 1 oil cooler bracket.

  36. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A00ORUX

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

  37. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A00OQO4

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

    2. Remove the O-ring from the No. 2 water by-pass pipe.

  38. REMOVE NO. 4 WATER BY-PASS HOSE

    A00ORW3

  39. REMOVE WATER INLET HOUSING


    1. A00OR7J

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  40. REMOVE FUEL HOSE PROTECTOR


    1. A00OUIW

      Remove the bolt and fuel hose protector.

  41. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A00OU7J

      Disconnect the exhaust fuel addition injector connector.

    2. A00OU58

      Turn the retainer as shown in the illustration.

    3. A00ORLS

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A00OTGY

      Remove the check valve and gasket.

      Text in Illustration
      A00OVAR Check Valve

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

  42. REMOVE NO. 3 FUEL HOSE

    A00ORMT

  43. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A00OURA

      Remove the check valve and gasket.

      Text in Illustration
      A00OVAR Check Valve

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

  44. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A00ORFG

      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. A00OTFG

      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 SWITCHING VALVE ASSEMBLY


    1. A00OV8YE01
      Text in Illustration
      *a Pinch

      Pinch the clip as shown in the illustration, and pull out the VSV connector.

    2. A00OR7I

      Disconnect the 2 vacuum hoses.

    3. Using a 4 mm hexagon socket wrench, remove the 2 bolts and VSV.

  48. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. Disconnect the vacuum regulating valve connector.

    2. A00OQVH

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  49. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A00OUD1

      Detach the 10 clamps and remove the 2 vacuum transmitting hoses.

  50. REMOVE VENTILATION HOSE

    A00OR6X

  51. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  52. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00OVQG

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

      Text in Illustration
      A00OV9Z Bolt
      A00OVAR Nozzle Holder Clamp Seat
      A00OVPJ Nut
    2. A00OT0Y

      Remove the cylinder head cover gasket from the cylinder head cover.

  53. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00OTUB

      Remove the 18 bolts and 2 nuts.

      Text in Illustration
      A00OVAR Nut
    2. A00OQGJE06

      Insert the blade of an oil pan seal cutter between the No. 2 oil pan and cylinder block, cut through the applied sealer and remove the No. 2 oil pan.

      Note


      • Do not use the oil pan seal cutter for the area between the oil pan and timing chain cover.

      • Be careful not to damage the contact surfaces of the No. 2 oil pan.

  54. REMOVE OIL FILTER ELEMENT


    1. A00OVMC

      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. A00OSJ5E01
      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. Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    7. A00OV5WE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    8. A00OUSIE01
      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.

  55. REMOVE OIL FILTER BRACKET


    1. A00OSI5

      Remove the 4 bolts and oil filter bracket.

    2. A00OVJR

      Remove the gasket from the oil filter bracket.

  56. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00OU5S

      Remove the 3 bolts and oil strainer.

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

  57. REMOVE CAMSHAFT POSITION SENSOR


    1. A00ORM7

      Remove the bolt and sensor.

  58. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A00OUGK

      Using a clip remover, remove the clip.

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

  59. REMOVE WATER PUMP ASSEMBLY


    1. A003DRL

      Remove the 7 bolts, water pump and gasket.

  60. 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 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 direction of engine revolution 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 )

  61. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00ORM9

      Remove the 13 bolts and seal washer.

      Text in Illustration
      A00OVAR Bolt and Seal Washer
    2. A00OTKY

      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.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A00OTIYE01
      Text in Illustration
      *1 Gasket
      *2 O-Ring

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

  62. REMOVE STRAIGHT SCREW PLUG


    1. A00OVWC

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

  63. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A00OT6O

      Place the timing chain cover on wooden blocks.

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  64. REPLACE STUD BOLT

    Tech Tips

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


    1. A00OU41E01

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

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