OIL PUMP REMOVAL

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • Fuel inlet pipe sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.


  1. REMOVE ENGINE ASSEMBLY

    Click here

  2. REMOVE ENGINE WIRE

  3. REMOVE INTERCOOLER AIR TUBE


    1. B007OCP

      Remove the 2 bolts and air tube support bracket.

    2. B007W8Q

      Disconnect the connector from the intake air temperature sensor.

    3. Loosen the hose clamp and remove the intercooler air tube from the diesel throttle body assembly.

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. B007UU2

      Disconnect the connector and clamp.

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

    3. B007V3W

      Disconnect the connector to remove the emission control valve wire from the diesel throttle body assembly.

  5. REMOVE NO. 2 WATER BY-PASS PIPE


    1. B007SRPE01

      Remove the 2 bolts and No. 2 water by-pass pipe.

  6. REMOVE DIFFERENTIAL PRESSURE SENSOR


    1. B007OTG

      Disconnect the connector from the differential pressure sensor.

    2. Remove the bolt and differential pressure sensor from the pipe clamp.

    3. B007WFS

      Slide the 2 clamps and disconnect the 2 air hoses from the No. 1 vacuum pipe and No. 2 vacuum pipe.

    4. B007VJ2

      Slide the 2 clamps and remove the 2 air hoses from the differential pressure sensor.

  7. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B007OTM

      Disconnect the 3 connectors from the 3 exhaust gas temperature sensors.

    2. B007R5C

      Remove the nut and disconnect the No. 3 exhaust gas temperature sensor from the No. 1 vacuum pipe.

    3. B007RWD

      Remove the bolt and open the clamp of the pipe clamp.

    4. Detach the 3 connectors from the pipe clamp.

    5. B007REK

      Using a 14 mm union nut wrench, remove the exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

    6. B007QVF

      Using a 14 mm union nut wrench, remove the No. 2 exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

    7. B007SY8

      Using a 14 mm union nut wrench, remove the No. 3 exhaust gas temperature sensor from the exhaust manifold converter sub-assembly.

  8. REMOVE NO. 1 VACUUM PIPE


    1. B007PSG

      Remove the nut and clamp from the No. 1 vacuum pipe and No. 2 vacuum pipe.

    2. B007PM0

      Using a 17 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-assembly.

  9. REMOVE NO. 2 VACUUM PIPE


    1. B007UD6

      Using a 17 mm union nut wrench, remove the No. 2 vacuum pipe from the exhaust manifold converter sub-assembly.

    2. B007V1T

      Remove the clamp from the pipe clamp.

  10. REMOVE PIPE CLAMP


    1. B007Q6K

      Remove the 3 bolts and pipe clamp from the engine cover bracket.

  11. REMOVE ENGINE COVER BRACKET


    1. B007SSV

      Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

  12. REMOVE GAS FILTER


    1. B007PAQ

      Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

    2. Remove the gas filter from the gas filter bracket.

  13. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. B007W37

      Disconnect the diesel turbo pressure sensor connector.

    2. Remove the bolt and diesel turbo pressure sensor.

    3. Disconnect the vacuum hose from the diesel turbo pressure sensor.

  14. REMOVE EGR VALVE BRACKET


    1. B007VJ5

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  15. REMOVE NO. 2 EGR PIPE


    1. B007TEN

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  16. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007R0N

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B007QH0

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    4. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  17. REMOVE CONNECTING WIRE


    1. B007SCR

      Disconnect the connector from the common rail assembly.

    2. Detach the 2 clamps and remove the connecting wire from the bracket.

  18. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B007TH8

      Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 gaskets from the exhaust manifold and electric EGR control valve assembly.

    3. B007S7R

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  19. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the connector from the vacuum control valve set.

    2. B007SNQ

      Disconnect the 2 vacuum hoses from the vacuum control valve set and No. 2 EGR valve assembly.

    3. B007OKL

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  20. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007P0OE01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
      *3 Water Hose

      Slide the clamp and disconnect the No. 6 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    2. Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    4. Remove the 2 bolts and No. 4 water by-pass pipe sub-assembly from the intake manifold.

  21. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. B007S1I

      Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly from the intake manifold.

  22. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B007OKOE01

      w/ No. 2 Fuel Pipe Clamp:

      Detach the No. 2 fuel pipe clamp from the engine oil level dipstick guide.

    2. Remove the engine oil level dipstick.

    3. Slide the clip and disconnect vacuum hose from the intake manifold.

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

    5. Remove the O-ring and grommet from the engine oil level dipstick guide.

  23. REMOVE NO. 2 FUEL PIPE


    1. B007ODP

      Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

    2. Remove the bolt and No. 2 fuel pipe from the manifold stay.

  24. REMOVE WIRING HARNESS CLAMP BRACKET

    B007VDT

    1. Disconnect the diesel throttle body assembly connector and pre-stroke control valve connector.

    2. B007USR

      Detach the 2 wire harness clamps.

    3. Remove the bolt and wiring harness clamp bracket.

  25. REMOVE MANIFOLD STAY

    B007QD1

    1. Remove the bolt and disconnect the wiring harness clamp bracket from the manifold stay.

    2. B007TF1

      Remove the 2 bolts and manifold stay.

  26. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    B007UXH

    1. Remove the fuel injection pump cover sub-assembly from the supply pump assembly.

  27. REMOVE FUEL PUMP MOTOR WIRE

    B007T5Y

    1. Disconnect the fuel pump motor wire connector and remove the fuel pump motor wire.

  28. REMOVE NO. 2 FUEL HOSE


    1. Slide the 2 clips and remove the No. 2 fuel hose from the supply pump assembly and No. 3 nozzle leakage pipe assembly.

  29. REMOVE NO. 1 FUEL HOSE

    B007RK7

    1. Slide the 2 clips and remove the No. 1 fuel hose from the supply pump assembly and No. 2 fuel pipe.

  30. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    B007PG4E01

    1. Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe Click here.

      Text in Illustration
      B007QIC Union Bolt
      B007T7S Bolt

    2. Remove the bolt from the intake manifold.

    3. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.

  31. REMOVE NO. 3 FUEL PIPE

    Click here

  32. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    B007VFTE01
    Text in Illustration
    *a Common Rail Assembly Side
    *b Fuel Supply Pump Assembly Side

    1. Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.

    2. B007UA6E01

      Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.

      SST
      09245-11010

      Note

      If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

    3. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.

  33. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    B007OBF

    1. Slide the 2 clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe assembly and common rail assembly.

    2. Slide the 2 clamps and remove the No. 5 fuel hose from the No. 1 nozzle leakage pipe assembly and No. 2 nozzle leakage pipe assembly.

    3. B007OEM

      Slide the clamp and disconnect the No. 6 fuel hose from the No. 3 nozzle leakage pipe assembly.

    4. Remove the 2 bolts and No. 2 nozzle leakage pipe assembly.

  34. REMOVE INTAKE MANIFOLD


    1. Remove the bolt and disconnect the wire harness bracket.

    2. B007WDY

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut

  35. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B007QHM

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  36. REMOVE NO. 1 FUEL PIPE


    1. B007QEC

      Remove the bolt, union bolt and gasket and disconnect the No. 1 fuel pipe from the cylinder head cover sub-assembly and exhaust fuel addition injector assembly.

    2. B007T63

      Disconnect the No. 4 fuel pipe and remove the No. 1 fuel pipe Click here.

  37. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Note

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    1. B007TI6E01

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      SST
      09245-11010
    2. B007RUW

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note

      When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  38. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B007QKO

      for Upper Side:

      Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

    2. B007VTZ

      for Rear Side:

      Remove the bolt and wiring harness clamp bracket from the cylinder block sub-assembly.

  39. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    1. B007TI6E01

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      SST
      09245-11010
    2. B007RUW

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note

      When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  40. REMOVE HOSE BRACKET


    1. B007VX5

      Remove the 2 bolts and bracket from the cylinder head sub-assembly.

  41. REMOVE COOLER COMPRESSOR ASSEMBLY

  42. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B007TMD

      Remove the 4 bolts and No. 1 compressor mounting bracket from the cylinder block sub-assembly, timing chain case assembly and timing chain cover sub-assembly.

  43. REMOVE PCV HOSE


    1. B007TJO

      Slide the 2 clips, detach the clamp and remove the PCV hose.

  44. REMOVE NO. 5 WATER BY-PASS HOSE


    1. B007QRF

      Slide the 2 clamps and disconnect the No. 5 water by-pass hose from the No. 1 injector holder and water outlet sub-assembly.

    2. Detach the clamp and remove the No. 5 water by-pass hose from the hose clamp.

  45. REMOVE NO. 4 WATER BY-PASS HOSE


    1. B007W47

      Slide the clamp and disconnect the No. 4 water by-pass hose from the No. 1 injector holder.

  46. REMOVE NO. 1 INJECTOR HOLDER


    1. B007QEK

      Disconnect the connector from the exhaust fuel addition injector assembly.

    2. B007R14

      Remove the 3 nuts and No. 1 injector holder from the exhaust manifold.

  47. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. B007QCY

      Remove the 3 nuts and No. 2 exhaust manifold heat insulator from the No. 1 injector holder.

    2. Remove the gasket.

  48. REMOVE AIR FUEL RATIO SENSOR

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B007V2LE01

      Disconnect the connector.

    2. Using SST, remove the air fuel ratio sensor.

      SST
      09224-00012

  49. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B007RRK

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.

  50. REMOVE NO. 1 TURBO INSULATOR


    1. B007OCV

      Remove the 3 bolts and No. 1 turbo insulator from the exhaust manifold and turbocharger sub-assembly.

  51. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY


    1. B007UCK

      Remove the bolt, 2 nuts and No. 2 exhaust pipe support stay from the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

  52. REMOVE EXHAUST PIPE SUPPORT STAY


    1. B007UH0

      Remove the 3 bolts and exhaust pipe support stay from the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

  53. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. B007V5F

      Remove the nut, exhaust pipe clamp and exhaust manifold converter sub-assembly from the turbocharger sub-assembly.

    2. Remove the gasket.

  54. REMOVE FRONT ENGINE MOUNTING INSULATOR RH

  55. REMOVE FRONT ENGINE MOUNTING INSULATOR

  56. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B007QGM

      Remove the 2 bolts, No. 1 water by-pass pipe and gasket from the timing chain cover sub-assembly.

  57. REMOVE NO. 1 AND NO. 2 TURBO WATER HOSE

    B007TM2

    1. Slide the clip and disconnect the No. 1 turbo water hose from the water pump assembly.

    2. Slide the clip and disconnect the No. 2 turbo water hose from the water outlet sub-assembly.

  58. REMOVE TURBOCHARGER STAY

    B007U06

    1. Remove the 3 bolts, nut and turbocharger stay.

  59. REMOVE TURBO OIL OUTLET PIPE

    B007U8Y

    1. Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe.

    2. Remove the 2 bolts, turbo oil outlet pipe and gasket.

  60. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    B007PZG

    1. Remove the union bolt and gasket.

    2. B007TW6
      B007QI6E01

      Remove the 2 nuts and turbo oil inlet pipe sub-assembly.

      Note

      Do not loosen the nut labeled A.

    3. Remove the gasket.

  61. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B007T2F

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the turbocharger sub-assembly.

  62. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007QJS

      Slide the clamp and disconnect the No. 3 water by-pass hose from the water outlet sub-assembly.

    2. Remove the 2 bolts and No. 2 water by-pass pipe sub-assembly from the engine water pump assembly and water inlet.

  63. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B007WFF

      Remove the 4 bolts, 2 nuts and water outlet sub-assembly from the timing chain cover sub-assembly.

    2. Remove the gasket from the timing chain cover sub-assembly.

  64. REMOVE WATER INLET


    1. B007OV8

      Remove the 2 bolts and water inlet from the engine water pump assembly.

  65. REMOVE THERMOSTAT


    1. Remove the thermostat from the engine water pump assembly.

    2. Remove the gasket from the thermostat.

  66. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. B007SJQ

      Remove the bolt and No. 1 idler pulley sub-assembly from the generator bracket sub-assembly.

  67. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B007SYU

      Remove the 3 bolts and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.

  68. REMOVE CRANKSHAFT PULLEY COVER


    1. B007Q6I

      Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.

  69. REMOVE CRANKSHAFT PULLEY


    1. B007T3PE01

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

      SST
      09213-58014
      09330-00021

      Tech Tips

      Make sure to leave the pulley bolt screwed into the crankshaft by 2 or 3 threads.

    2. B007QBJE01

      Using SST, remove the pulley bolt and crankshaft pulley from the crankshaft.

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

  70. REMOVE NO. 1 ENGINE HANGER


    1. B007T7O

      Remove the 2 bolts and No. 1 engine hanger from the cylinder head sub-assembly.

  71. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. B007QO3

      Remove the 4 bolts and generator bracket sub-assembly from the cylinder head sub-assembly and timing chain case assembly.

  72. REMOVE INJECTOR ASSEMBLY


    1. B007TDF

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

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

      When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

    3. Remove the O-ring from each injector assembly.

  73. REMOVE NOZZLE HOLDER GASKET


    1. B007QQT

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

  74. REMOVE CAMSHAFT POSITION SENSOR


    1. B007QAN

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor from the cylinder head cover sub-assembly.

  75. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B007UOG

      Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut
      B007T7S Nozzle Holder Clamp Seat
    2. B007SGUE01
      Text in Illustration
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
      *3 Camshaft Bearing Cap Oil Hole Gasket

      Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets from the cylinder head cover sub-assembly.

  76. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the engine oil level sensor connector.

    2. B007TS3

      Remove the 4 bolts and engine oil level sensor from the oil pan sub-assembly.

  77. REMOVE OIL PAN SUB-ASSEMBLY


    1. B007SYK

      Remove the 2 nuts and 23 bolts.

      Text in Illustration
      B007USN Bolt
      B007QIC Nut
    2. B007VVO

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-assembly, cut off the applied sealer and remove the oil pan sub-assembly.

      Note


      • Be careful not to damage the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

      • Be careful not to damage the cylinder block sub-assembly flange.

  78. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

    2. B007P6ZE01
      Text in Illustration
      *a Timing Mark

      Align the timing mark of the crankshaft pulley and timing chain cover sub-assembly by rotating the crankshaft clockwise.

    3. Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Tech Tips

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/compression).

  79. REMOVE FAN PULLEY


    1. B007U1M

      Remove the 8 bolts, engine water pump assembly and gasket from the timing chain case assembly.

  80. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B007U1M

      Remove the 8 bolts, engine water pump assembly and gasket from the timing chain case assembly.

  81. REMOVE TIMING CHAIN COVER PLATE

    B007UOY

    1. Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  82. REMOVE SUPPLY PUMP ASSEMBLY

    Note

    Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.

    B007UY5

    1. B007T89E01
      Text in Illustration
      *a Hold
      B007USN Turn

      Using SST, hold the crankshaft pulley and loosen the supply pump shaft nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      Note

      Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.

      Tech Tips

      Rotate the supply pump shaft nut once to loosen it.

    2. B007S55E01
      Text in Illustration
      *a Engine Front Side
      *b Engine Rear Side
      *c Hexagonal Portion

      Install SST to the timing chain cover sub-assembly with the 3 bolts.

      SST
      09241-11010
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips


      • Make sure that the installation direction of SST is as shown in the illustration.

      • B007TPDE01

        Align the hexagonal portion of SST with the supply pump shaft nut to install SST.

    3. B007S30

      Remove the 2 bolts and No. 1 fuel pump bracket from the cylinder block sub-assembly and supply pump assembly.

    4. B007VWW

      Loosen the 3 nuts to the ends of the stud bolts.

      Note

      Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.

    5. B007VQ4E01

      Using SST, loosen the supply pump shaft nut and detach the supply pump assembly and injection pump drive gear.

    6. Remove the 3 nuts from the stud bolts.

    7. Remove the O-ring from the supply pump assembly.

    8. Remove SST from the timing chain cover sub-assembly.

    9. B007P27

      Remove the supply pump shaft nut from the timing chain cover sub-assembly service hole.

    10. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

  83. REMOVE INJECTION PUMP INSULATOR


    1. B007SAN

      Remove the injection pump insulator from the cylinder block sub-assembly.

  84. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B007U1K

      Remove the 20 bolts from the timing chain cover sub-assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the points in the illustration.

      B007OC2E01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain cover sub-assembly and timing chain case assembly.

    3. B007WDC

      Remove the timing chain case gasket from the timing chain case assembly.

  85. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B007UX8E01
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Using a screwdriver and wooden block, pull out the front crankshaft oil seal.

      Note

      Do not damage the surface of the front crankshaft oil seal press fit hole.

  86. INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR


    1. B007VM4

      Using a dial indicator, measure the backlash.

      Standard gear backlash
      0.02 to 0.3 mm (0.000787 to 0.0118 in.)
      Maximum gear backlash
      0.42 mm (0.0165 in.)

      If the gear backlash is more than the maximum, replace the timing chain case assembly or oil pump drive gear.

  87. REMOVE OIL PUMP DRIVE GEAR


    1. B007SVR

      Remove the oil pump drive gear from the crankshaft.

  88. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 3 chain tensioner assembly, the plunger and 2 springs may come off of the No. 3 chain tensioner assembly body, but this is not a malfunction.

    • B007QXYE01

      Before installing the plunger and 2 springs to the No. 3 chain tensioner assembly body, check that they are free of foreign matter and not damaged.


    1. B007QUBE01
      Text in Illustration
      *a No. 3 Chain Tensioner Assembly Body
      *b Spring
      *c Plunger

      Fully insert the plunger, align the No. 3 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

    2. B007PO8
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Remove the 2 bolts, No. 3 chain tensioner assembly and gasket from the engine balancer assembly.

  89. REMOVE NO. 1 BALANCE SHAFT THRUST PLATE


    1. B007UTC

      Remove the bolt and No. 1 balance shaft thrust plate from the balance shaft gear sub-assembly.

  90. REMOVE BALANCE SHAFT TIMING SPROCKET, BALANCE SHAFT GEAR SUB-ASSEMBLY AND NO. 3 CHAIN SUB-ASSEMBLY


    1. B007UGV

      Remove the balance shaft timing sprocket, balance shaft gear sub-assembly with No. 3 chain sub-assembly from the crankshaft and engine balancer assembly.

  91. REMOVE TIMING CHAIN GUIDE


    1. B007UUA

      Remove the bolt and timing chain guide from the cylinder head sub-assembly.

  92. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B007UAXE01
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate clockwise to release the lock. Once the lock is released, push the plunger into the No. 2 chain tensioner assembly.

    2. B007R4ME01
      Text in Illustration
      *a Pin

      Move the stopper plate counter clockwise to set the lock, and then insert a pin into the stopper plate hole.

    3. B007UIH

      Remove the 2 bolts and No. 2 chain tensioner assembly from the timing chain case assembly.

  93. REMOVE NO. 2 CHAIN TENSIONER SLIPPER


    1. B007W1P

      Remove the bolt and No. 2 chain tensioner slipper from the timing chain case assembly.

  94. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B007OQ6

      Remove the 2 bolts and No. 2 chain vibration damper from the timing chain case assembly.

  95. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. Remove the No. 2 chain sub-assembly from the camshaft timing sprockets and injection pump drive gear.

  96. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the pin is removed from the No. 1 chain tensioner assembly, the plunger and spring may come off of the No. 1 chain tensioner assembly body, but this is not a malfunction.

    • B007SLVE01

      Before installing the plunger and spring to the No. 1 chain tensioner assembly body, check that they are free of foreign matter and not damaged.

    Text in Illustration
    *a No. 1 Chain Tensioner Assembly Body
    *b Spring
    *c Plunger

    1. B007UVRE01
      Text in Illustration
      *a Pin
      *b Plunger
      *c Plunger Groove

      Fully insert the plunger, align the No. 1 chain tensioner assembly body hole with the plunger groove and insert the pin as shown in the illustration.

    2. Remove the 2 bolts, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

  97. REMOVE NO. 1 CHAIN TENSIONER SLIPPER


    1. B007TRS

      Remove the No. 1 chain tensioner slipper from the straight pin.

  98. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B007OLR

      Remove the bolt and No. 1 chain vibration damper from the cylinder block sub-assembly.

  99. REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY


    1. B007TM1

      Remove the crankshaft timing sprocket, injection pump drive gear with No. 1 chain sub-assembly from the crankshaft and supply pump shaft.

  100. REMOVE CAMSHAFT TIMING SPROCKET


    1. for Exhaust Side:


      1. B007R2WE01
        Text in Illustration
        *a Hold
        B007USN Turn

        Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the No. 2 camshaft.

        Note

        Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

    2. for Intake Side:


      1. B007STWE01
        Text in Illustration
        *a Hold
        B007USN Turn

        Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing sprocket bolt and camshaft timing sprocket from the camshaft.

        Note

        Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

  101. REMOVE TIMING CHAIN CASE ASSEMBLY


    1. B007PU8

      Remove the 15 bolts from the timing chain case assembly.

    2. Using a screwdriver wrapped in protective tape, remove the timing chain case assembly by prying the points in the illustration.

      B007P4OE01
      Text in Illustration
      *a Protective Tape - -

      Note

      Do not damage the contacting surfaces of the timing chain case assembly, cylinder head sub-assembly and cylinder block sub-assembly.

    3. B007OFG

      Remove the 4 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.

    4. B007US2

      Remove the No. 2 water pump gasket from the timing chain case assembly.