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.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE ENGINE ASSEMBLY

    Click here

  3. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E02G

      Remove the bolt and clamp.

    2. A01E1CP

      Remove the bolt and oil level gauge guide.

    3. A01E0LTE03

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  4. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE

    Click here

  5. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      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. A01DVY2E05

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  6. 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. A01E177

      Remove the 3 bolts and disconnect the 4 connectors.

    2. A01DXC5E01

      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. A01DZGHE01

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

    5. A01DV31

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

  7. REMOVE TIMING BELT


    1. A01DWQTE02

      Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

    2. A01E0E0E01

      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

      A01DW3FE01

      • 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.

  8. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      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 the camshaft timing pulley.

    2. Remove the camshaft timing pulley.

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

  10. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  11. REMOVE NO. 2 TIMING BELT COVER


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

  12. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

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

  13. REMOVE TIMING GEAR COVER INSULATOR


    1. A01E2IH

      Remove the bolt and timing gear cover insulator.

  14. REMOVE VACUUM PUMP ASSEMBLY


    1. Disconnect the vacuum hose.

    2. A01DVEJE01

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

  15. 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.

  16. REMOVE PUMP DRIVE SHAFT PULLEY


    1. A01DVN8E01

      Remove the 4 bolts, No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    2. A01E0MBE01

      Using SST, hold the crankshaft pulley and remove the nut and O-ring.

      SST
      09213-58013
      09330-00021

  17. REMOVE CRANKSHAFT PULLEY


    1. A01E1JVE02

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01DWXXE02

      Using SST, remove the crankshaft 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.

  18. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DY98

      Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  19. REMOVE CRANKSHAFT POSITION SENSOR

    A01DZC3

    1. Disconnect the sensor connector.

    2. Remove the 3 clips, bolt and sensor.

  20. REMOVE TIMING GEAR COVER


    1. Remove the wire harness clamp.

    2. A01DWDME01

      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.

  21. REMOVE NO. 1 IDLE GEAR


    1. A01DZ74E09
      Text in Illustration
      *1 Service Bolt

      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.

  22. REMOVE CRANKSHAFT TIMING GEAR


    1. Remove the No. 1 crankshaft sensor plate.

    2. A01DYA2E01

      Using SST, remove the crankshaft timing gear.

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

  23. REMOVE INJECTION GEAR


    1. A01DWERE02

      Using SST, remove the injection gear.

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

  24. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01DVYA

      Disconnect the 2 fuel hoses.

    2. A01DZOI

      Disconnect the 2 connectors.

    3. A01E0LPE01

      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. A01E0MBE02

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

      SST
      09213-58013
      09330-00021
    6. A01DXRJ

      Loosen the 2 nuts.

    7. A01DVLSE01

      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.

  25. REMOVE OIL DIPSTICK GUIDE


    1. A01DV94E01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      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.

  26. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 22 bolts and 2 nuts.

    2. A01DXTOE04

      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.

  27. REMOVE TIMING GEAR CASE ASSEMBLY


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

    2. A01E17DE01

      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.