OIL PUMP (w/o 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.


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. A01E0I5

      Remove the 6 bolts and timing belt cover.

  3. 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.

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

  5. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY


    1. A01DZH8E02

      Disconnect the connector.

    2. Remove the 2 bolts and viscous with magnet clutch heater assembly.

  6. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly.

  7. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  8. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  9. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner assembly.

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Remove the 4 bolts and No. 1 compressor mounting bracket.

  12. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)


    1. A01DYJJ

      Disconnect the vacuum switching valve connector.

    2. A01DZ46

      Disconnect the 3 vacuum transmitting hoses.

    3. A01DWYI

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

  13. REMOVE MANIFOLD STAY (w/o Intercooler)


    1. A01E344E01

      Remove the 2 bolts and manifold stay.

  14. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E03WE11
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

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

  15. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)


    1. A01DZU2

      Disconnect the 2 connectors.

    2. A01E2KU

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

  16. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


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

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


    1. w/ Intercooler:


      1. A01DWWA

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

      2. A01E1SS

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

      3. A01DXC6E01
        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.

    2. w/o Intercooler:


      1. A01DXPXE02
        Text in Illustration
        *1 No. 2 Injection Pipe Clamp
        *2 No. 3 Injection Pipe Clamp
        *a Injector Side
        *b Common Rail Side

        Remove the bolt and No. 2 injection pipe clamp.

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

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

  17. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  18. DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.

  19. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)


    1. w/ Intercooler:


      1. A01DZHP

        Disconnect the 2 connectors.

      2. A01E31V

        Disconnect the 6 vacuum hoses.

      3. Remove the bolt and No. 1 gas filter with gas filter bracket.

      4. A01DY7U

        Remove the 2 bolts and electric vacuum regulating valve.

    2. w/o Intercooler:


      1. A01DWIO

        Disconnect the connector.

      2. Disconnect the 2 vacuum hoses.

      3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.

        Note

        Do not remove the electric vacuum regulating valve from the bracket.

  20. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DZS6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  21. REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  22. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DX9H

      Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

  23. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

    If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.


    1. w/ Intercooler:


      1. A01E10I

        Remove the bolt and disconnect the injection pipe clamp.

      2. A01DVY2E07
        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. 4 injection pipe.

    2. w/o Intercooler:


      1. A01E0ZRE01

        Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      2. A01E2XGE02
        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. 4 injection pipe.

  24. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVNTE01
      Text in Illustration
      *1 Union Bolt

      w/ Intercooler:

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

    3. A01DYKDE01
      Text in Illustration
      *1 Union Bolt

      w/o Intercooler:

      Remove the union bolt, 2 bolts, No. 2 nozzle leakage pipe and gasket.

  25. 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 injector connectors.

    2. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying 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.

  26. 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.

  27. REMOVE NO. 2 TIMING BELT COVER


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

  28. REMOVE ENGINE WATER PUMP ASSEMBLY

    A01DWA8

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

  29. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DVEJE01

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

  30. REMOVE VANE PUMP ASSEMBLY


    1. A01E0JL

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

  31. REMOVE PUMP DRIVE SHAFT PULLEY


    1. A01DVN8E01

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

    2. A01E0MBE03

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

      SST
      09213-58014
      09330-00021

  32. 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.

  33. REMOVE CAMSHAFT POSITION SENSOR


    1. Remove the bolt and camshaft position sensor.

  34. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and crankshaft position sensor.

  35. REMOVE TIMING GEAR COVER


    1. A01DWDME01

      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.

  36. REMOVE NO. 1 IDLE GEAR


    1. A01DZ74E09
      Text in Illustration
      *1 Service Bolt

      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. Remove the 2 bolts and thrust plate.

    3. Remove the service bolt.

    4. Turn the No. 2 idle sub gear and align the gear teeth of the No. 1 idle gear and No. 2 idle sub gear.

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

    6. Remove the idle gear shaft.

  37. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DW5HE01

      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 )

  38. REMOVE INJECTION GEAR


    1. A01DWERE01

      Using SST, remove the injection gear.

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

  39. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    A01DW6AE01

    1. Remove the bolt and clamp.

    2. Remove the 2 bolts and oil level gauge guide.

    3. A01E03WE07

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

    4. A01DYSWE01

      Disconnect the 2 fuel hoses.

    5. A01DXJEE01

      Disconnect the 2 connectors.

    6. A01E0LPE01

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

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

    8. A01E0MBE02

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

      SST
      09213-58013
      09330-00021
    9. A01E141E01

      Loosen the 2 nuts.

    10. 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.

    11. Remove the 2 nuts and pump.

      Note


      • Do not hold the pump or carry it holding the pipe.

      • The pump must be kept horizontal.

    12. Remove the O-ring.

  40. REMOVE ENGINE OIL LEVEL DIPSTICK

  41. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the bolt and dipstick guide.

    2. Remove the O-ring from the dipstick guide.

  42. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 22 bolts and 2 nuts.

    2. A01DXTOE03

      Insert the blade of an 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 the oil pan seal cutter for the timing gear case and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

    3. Clean off any sealer remaining on the oil pan and cylinder block.

  43. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. Remove the 2 bolts, nut, oil strainer and gasket.

  44. REMOVE TIMING GEAR CASE ASSEMBLY


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

    2. A01E17DE01

      Remove the 8 bolts and union bolt. Then remove the timing gear case and 2 O-rings.

      Note

      Do not drop the oil pump rotor.

    3. Remove the gasket.