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

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  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 VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY


    1. A01DZH8E02

      Disconnect the connector.

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

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


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

  6. REMOVE NO. 2 IDLE PULLEY ASSEMBLY

  7. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  8. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

      Remove the 4 bolts and V-ribbed belt tensioner.

  10. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


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

  11. REMOVE MANIFOLD STAY


    1. w/ EGR Cooler:


      1. Disconnect the 2 VSV connector and 3 vacuum hoses.

      2. A01E1Y6

        Remove the 2 bolts and manifold stay.

    2. w/o EGR Cooler:


      1. A01E344E01

        Remove the 2 bolts and manifold stay.

  12. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Remove the engine oil level dipstick.

    2. A01DW6AE01

      Remove the bolt and clamp.

    3. Remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring engine oil level dipstick guide.

    5. A01E03WE03

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

  13. 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. A01E30RE05

      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.

  14. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E0ZRE01

      Remove the 2 bolts.

      Note

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

    2. A01E2XGE01

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

  15. 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. A01DXL9E02

      Disconnect the ventilation hose.

    2. Disconnect the 4 injector connectors.

    3. A01DXC5E01

      Using a small screwdriver, remove the 4 nozzle holder seals by prying the portion between each nozzle holder seal and the cutout part of the cylinder head cover.

    4. A01DZGHE01

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

    5. A01DV31

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

  16. REMOVE CAMSHAFT TIMING PULLEY

    A01DV9RE01

    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.

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

  18. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and timing belt cover.

  19. REMOVE WATER PUMP ASSEMBLY

    A01DWA8

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

  20. REMOVE VACUUM PUMP ASSEMBLY


    1. A01DVEJE01

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

  21. REMOVE VANE PUMP ASSEMBLY


    1. A01E0JL

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

  22. 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

  23. REMOVE CRANKSHAFT PULLEY


    1. A01E1JVE02

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01DWXXE02

      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.

  24. REMOVE CAMSHAFT POSITION SENSOR


    1. Remove the bolt and camshaft position sensor.

  25. REMOVE CRANKSHAFT POSITION SENSOR


    1. Remove the bolt and crankshaft position sensor.

  26. 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.

  27. REMOVE NO. 1 IDLE GEAR


    1. A01DZ74E01

      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.

  28. 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 )

  29. REMOVE INJECTION GEAR


    1. A01DWERE01

      Using SST, remove the injection gear.

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

  30. 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.

  31. REMOVE ENGINE OIL LEVEL DIPSTICK

  32. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the bolt and dipstick guide.

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

  33. 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.

  34. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  35. 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.