OIL PUMP (for DPF) 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. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  4. REMOVE ENGINE ASSEMBLY

    Click here

  5. REMOVE NO. 1 TIMING BELT COVER


    1. A01E1VTE01

      Remove the 6 bolts, 6 washers and timing belt cover.

  6. REMOVE TIMING BELT


    1. A01DWQTE05
      Text in Illustration
      *1 Timing Mark

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

      Tech Tips

      If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

    2. A01E0E0E01

      Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

    3. Remove the timing belt.

      Tech Tips

      A01DYCXE02

      • If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.

      • When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.

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

    Note

    When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.


    1. Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

  8. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)

    Click here

  9. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. Remove the 4 bolts and No. 1 viscous heater bracket.

  10. REMOVE NO. 2 IDLE PULLEY ASSEMBLY


    1. Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

  11. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  12. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner.

  14. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


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

  15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND COOLER

    Click here

  16. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01E26N

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

  17. REMOVE NO. 2 FUEL PIPE


    1. A01DZ44

      Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.

    2. A01DWSC

      Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

    3. Remove the fuel check valve, union bolt and 2 gaskets.

    4. Remove the 3 bolts and No. 2 fuel pipe.

  18. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DZSF

      Disconnect the 3 fuel hoses.

      Text in Illustration
      A01DZ8Z Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  19. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01E159

      Remove the 2 bolts.

      Text in Illustration
      A01DZ8Z Union Bolt

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

  20. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DYAV

      Remove the 3 bolts and No. 2 cylinder head cover.

  21. 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. 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.

    2. Disconnect the ventilation hose.

    3. A01DYWG

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

    4. A01DV31

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

  22. 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.

  23. REMOVE NO. 2 TIMING BELT COVER


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

  24. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

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

  25. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DVEJE01

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

  26. REMOVE VANE PUMP ASSEMBLY


    1. A01E0JL

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

  27. REMOVE CAMSHAFT POSITION SENSOR

    A01E329

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  28. REMOVE CRANKSHAFT POSITION SENSOR


    1. Disconnect the sensor connector.

    2. Remove the 3 clips, bolt and sensor.

      A01DVCJ

  29. 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
      09213-58014
      09330-00021

  30. REMOVE CRANKSHAFT PULLEY


    1. A01E21RE01

      Using SST, hold the crankshaft pulley and loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01E046E01

      Using SST, remove the pulley bolt and 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.

  31. REMOVE TIMING GEAR COVER

    Note

    As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.

    Tech Tips

    To prevent the injection gear from falling, temporarily install the fuel supply pump.


    1. A01DX9G

      Remove the 14 bolts and 2 nuts.

    2. A01E1WE

      Pry the timing gear cover at the locations shown in the illustration and remove the timing gear cover.

      Note

      Be careful not to drop the injection gear.

    3. A01DXPAE01

      Remove the O-ring from the timing gear case.

  32. REMOVE INJECTION GEAR


    1. A01E1H8

      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. A01E0AU

      Remove the injection gear.

  33. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01DYY9

      Remove the No. 1 crankshaft position sensor plate.

  34. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DVI0E01

      Using SST, remove the crankshaft timing gear.

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

  35. REMOVE IDLE GEAR THRUST PLATE


    1. A01E196

      Remove the 2 bolts and idle gear thrust plate.

  36. REMOVE NO. 1 IDLE GEAR


    1. A01DZHW

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

  37. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01DXLD

      Remove the No. 1 idle gear shaft.

  38. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. Disconnect the 2 fuel hoses.

    2. Disconnect the fuel temperature sensor connector and suction control valve connector from the fuel supply pump.

    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. A01E0MBE04

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

      SST
      09213-58014
      09330-00021
    6. A01DYM7

      Loosen the 2 nuts.

    7. A01DVLSE02

      Using SST, disconnect the fuel supply 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 fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    9. Remove the O-ring.

  39. 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 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 area between the oil pan and timing belt case, or for the area between the oil pan and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  40. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  41. REMOVE TIMING GEAR CASE ASSEMBLY


    1. A01DW4JE01

      Remove the union bolt and 8 bolts.

    2. A01E13M

      Pry the timing gear case at the location shown in the illustration and remove the gear case and gasket.

    3. A01DZBXE03

      Remove the 2 O-rings.