OIL PUMP REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


  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

    Click here

  4. REMOVE VACUUM PUMP ASSEMBLY


    1. A004TAZ

      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. A004PBSE02
      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. A004Q5A

      Remove the bolt and No. 1 idler pulley.

  7. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A004O6QE01
      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. A004UBG

      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. A004OKR

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

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A004QP0

      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. A004QEBE02
      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. A004O8S

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

  12. REMOVE NO. 7 WATER BY-PASS HOSE

    Click here

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  14. REMOVE EGR VALVE BRACKET


    1. A004RTK

      Remove the 3 bolts and 2 EGR valve brackets.

  15. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A004R37

      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

    Click here

  19. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  20. REMOVE NO. 4 FUEL HOSE

    A004TJI

  21. REMOVE COMMON RAIL ASSEMBLY


    1. A004NHM

      Remove the 2 bolts and common rail.

  22. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  23. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A004NMD

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  24. REMOVE NO. 1 GAS FILTER

    Click here

  25. REMOVE GAS FILTER BRACKET

    Click here

  26. REMOVE ENGINE COVER BRACKET

    Click here

  27. REMOVE NO. 2 INTAKE MANIFOLD

    Click here

  28. REMOVE INTAKE MANIFOLD

    Click here

  29. REMOVE WATER BY-PASS HOSE

    Click here

  30. REMOVE OIL COOLER ASSEMBLY

    Click here

  31. REMOVE NO. 6 WATER BY-PASS HOSE

    A004N0K

  32. REMOVE NO. 8 WATER BY-PASS HOSE

    A004P93

  33. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A004QEV

      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. A004P27

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

  35. REMOVE NO. 1 OIL COOLER BRACKET


    1. A004TYPE01
      Text in Illustration
      *A for CCo
      *B for DPF
      A004NAK Nut

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

    2. for CCo:

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

    3. for DPF:

      Remove the 3 gaskets from the No. 1 oil cooler bracket.

  36. REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A004OQH

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

  37. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A004RK6

      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

    A004RYZ

  39. REMOVE WATER INLET HOUSING


    1. A004OQ1

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  40. REMOVE NO. 2 FUEL PIPE (for CCo)

    Click here

  41. REMOVE FUEL HOSE PROTECTOR (for DPF)

    Click here

  42. REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)

    Click here

  43. REMOVE NO. 3 FUEL HOSE

    A004SQF

  44. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A004QZE

      Remove the check valve and gasket.

      Text in Illustration
      A004NAK Check Valve

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

  45. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    Click here

  46. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A004QLO

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  47. REMOVE INJECTOR ASSEMBLY

    Click here

  48. REMOVE VACUUM REGULATING VALVE ASSEMBLY (for CCo)

    Click here

  49. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  50. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A004RS0

      for CCo:

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

    2. A004TEN

      for DPF:

      Detach the 8 clamps and remove the 2 vacuum transmitting hoses.

  51. REMOVE NO. 1 WIRING HARNESS CLAMP BRACKET (for DPF)


    1. A004O2O

      Remove the bolt and No. 1 wiring harness clamp bracket.

  52. REMOVE VENTILATION HOSE

    A004RKE

  53. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  54. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A004NFN

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

      Text in Illustration
      A004NPW Bolt
      A004NAK Nozzle Holder Clamp Seat
      A004PZH Nut
    2. A004MV5

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

  55. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A004TA6E01
      Text in Illustration
      *A for CCo
      *B for DPF
      A004NAK Nut

      Remove the 18 bolts and 2 nuts.

    2. A004MX7

      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.

  56. REMOVE OIL FILTER ELEMENT

    Click here

  57. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY (for DPF)

    Click here

  58. REMOVE OIL FILTER BRACKET


    1. A004SPPE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the 4 bolts and oil filter bracket.

    2. A004U0KE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Remove the gasket from the oil filter bracket.

  59. REMOVE OIL CHECK VALVE SUB-ASSEMBLY (for DPF)


    1. A004T3H

      Using a 5 mm hexagon wrench, remove the bolt and oil check valve from the oil filter bracket.

  60. INSPECT OIL CHECK VALVE SUB-ASSEMBLY (for DPF)


    1. A004QSAE04
      Text in Illustration
      *1 Ball

      Push the ball of the oil check valve to check if it is stuck.

      If the check valve is stuck, replace the oil check valve sub-assembly.

  61. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A004NWR

      Remove the 3 bolts and oil strainer.

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

  62. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  63. DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A004Q8NE01
      Text in Illustration
      *A for CCo
      *B for DPF

      Using a clip remover, remove the clip.

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

  64. REMOVE WATER PUMP ASSEMBLY

    Click here

  65. REMOVE CRANKSHAFT PULLEY

    Click here

  66. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove the 13 bolts and seal washer.

      A004PZWE01
      Text in Illustration
      *A for CCo *B for DPF
      A004NAK Bolt and Seal Washer - -

    2. 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.

      A004NT9E01
      Text in Illustration
      *A for CCo *B for DPF

      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. A004SZEE02
      Text in Illustration
      *A for CCo
      *B for DPF
      *1 Gasket
      *2 O-Ring

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

  67. REMOVE STRAIGHT SCREW PLUG

    Tech Tips

    It is not necessary to replace the straight screw plug if there is no damage to the straight screw plug and no sign of oil leaks.


    1. A004QXO

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

  68. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A004QF3

      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.

  69. REPLACE STUD BOLT

    Tech Tips

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


    1. A004RXTE03
      *1 34 mm (1.34 in.)
      *2 25 mm (0.984 in.)
      *3 9.0 mm (0.354 in.)

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

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