OIL PUMP (w/ EGR Cooler) 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.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE ENGINE ASSEMBLY
1. Remove the engine Click here.
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
1. Remove the bolt and clamp.
2. Remove the bolt and oil level gauge guide.
3. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE
1. Remove the EGR cooler with electric EGR control valve and No. 2 EGR valve Click here.
REMOVE NO. 4 INJECTION PIPE
1. Remove the bolt and disconnect the injection pipe clamp.
  
  Note
  
  If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
2. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
REMOVE VENTILATION PIPE
1. Remove the bolt and disconnect the ventilation pipe from the cylinder head cover.
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. Remove the 3 bolts and disconnect the 4 connectors.
2. Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.
3. Disconnect the ventilation hose.
4. Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
5. Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
REMOVE TIMING BELT
1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
2. Uniformly loosen the 2 bolts and remove the timing belt tensioner.
3. Remove the timing belt.
4. Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.
  Tech Tips
  
  When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.
  
  When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks, as shown in the illustration.
REMOVE CAMSHAFT TIMING PULLEY
1. Remove the bolt of the camshaft timing pulley by holding the camshaft with a wrench.
  
  Note
  
  Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.
2. Remove the camshaft timing pulley.
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
REMOVE CYLINDER BLOCK INSULATOR
1. Remove the cylinder block insulator form the head.
REMOVE NO. 2 TIMING BELT COVER
1. Remove the 4 bolts, nut and timing belt cover.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 2 nuts, 5 bolts, water pump and gasket.
REMOVE TIMING GEAR COVER INSULATOR
1. Remove the bolt and timing gear cover insulator.
REMOVE VACUUM PUMP ASSEMBLY
1. Disconnect the vacuum hose.
2. Remove the 2 nuts, vacuum pump and 2 O-rings.
REMOVE VANE PUMP ASSEMBLY
1. Remove the 2 nuts, vane pump and O-ring.
  
  Tech Tips
  
  It is not necessary to remove the hose from the vane pump. For the remaining removal procedures, you may put the removed assembly aside in an appropriate location.
REMOVE PUMP DRIVE SHAFT PULLEY
1. Remove the 4 bolts, No. 2 camshaft timing pulley flange and pump drive shaft pulley.
2. Using SST, hold the crankshaft pulley and remove the nut and O-ring.
  
  SST
  
  09213-58013
  
  09330-00021
REMOVE CRANKSHAFT PULLEY
1. Using SST, remove the pulley bolt.
  
  SST
  
  09213-58014
  
  09330-00021
2. Using SST, remove the pulley.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
  
  Note
  
  Apply oil or grease to the threads and tip of SST (center bolt) before using it.
REMOVE CAMSHAFT POSITION SENSOR
1. Disconnect the sensor connector.
2. Remove the bolt and sensor.
REMOVE CRANKSHAFT POSITION SENSOR
1. Disconnect the sensor connector.
2. Remove the 3 clips, bolt and sensor.
REMOVE TIMING GEAR COVER
1. Remove the wire harness clamp.
2. Remove the 14 bolts and 2 nuts.
3. Using a slotted screwdriver, gently separate the cover from the timing gear case.
  
  Tech Tips
  
  There are tiny slots that allow you to insert the slotted screwdriver tip for separating the timing gear case and its cover. Refer to the illustration for the slot locations.
  
  Note
  
  Be careful not to damage the contact surfaces of the timing gear case and its cover.
4. Remove the cover and O-ring.
REMOVE NO. 1 IDLE GEAR
1. Secure the idle gears to the idle gear with the service bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Note
  
  If the screw bole position of the rear sub idle gear is incorrect, rotate the crankshaft counterclockwise to correct the hole position. Then install the service bolt.
2. Remove the 2 bolts and thrust plate.
3. Remove the service bolt.
4. Turn the sub gear and align the gear teeth of the idle main gear and sub gear.
5. Remove the idle gear and sub gear.
6. Remove the idle gear shaft.
REMOVE CRANKSHAFT TIMING GEAR
1. Remove the No. 1 crankshaft sensor plate.
2. Using SST, remove the crankshaft timing gear.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05010 )
REMOVE INJECTION GEAR
1. Using SST, remove the injection gear.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
REMOVE FUEL SUPPLY PUMP ASSEMBLY
1. Disconnect the 2 fuel hoses.
2. Disconnect the 2 connectors.
3. Remove the 4 bolts indicated by the arrows in the illustration.
4. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.
5. Remove the set nut and O-ring while holding the crankshaft pulley by using SST.
  
  SST
  
  09213-58013
  
  09330-00021
6. Loosen the 2 nuts.
7. Using SST, disconnect the 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.
8. Remove the 2 nuts and pump.
  Note
  - Do not hold the pump or carry it holding the pipe.
  - The pump must be kept horizontal.
9. Remove the O-ring.
REMOVE OIL DIPSTICK GUIDE
1. Remove the bolt and injection pipe clamp.
2. Remove the bolt and engine oil level dipstick guide.
3. Remove the O-ring from the engine oil level dipstick guide.
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 22 bolts and 2 nuts.
2. Insert the blade of a oil pan seal cutter between the cylinder block and oil pan. Cut through the applied sealer and remove the oil pan.
  Note
  
  Do not use a oil pan seal cutter for the timing gear case and rear oil seal retainer.
  
  Be careful not to damage the oil pan flange.
3. Remove the 2 bolts, nut, oil strainer and gasket.
4. Clean off any sealer remaining on the oil pan and cylinder block.
REMOVE TIMING GEAR CASE ASSEMBLY
1. Remove the nut and No. 1 vacuum transmitting pipe.
2. Remove the union bolt and 8 bolts. Then remove the timing gear case and its 2 O-rings.
  
  Tech Tips
  
  Pry the gear case in the location shown in the illustration.
  
  Note
  
  Do not drop the oil pump rotor.
3. Remove the oil pump gasket.