OIL PUMP (w/ 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.

  • 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 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

  3. REMOVE ENGINE ASSEMBLY

    Click here

  4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E02G

      Remove the bolt and clamp.

    2. A01E1CP

      Remove the bolt and oil level gauge guide.

    3. A01E0LTE02

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

  5. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE

    Click here

  6. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

    2. A01DVY2E02

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

  7. 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. A01E177

      Remove the 3 bolts and disconnect the 4 connectors.

    2. A01DXC5E01

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

    3. Disconnect the ventilation hose.

    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.

  8. REMOVE TIMING BELT

    Click here

  9. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      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.

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

  11. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  12. REMOVE NO. 2 TIMING BELT COVER


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

  13. REMOVE WATER PUMP ASSEMBLY


    1. A01DWA8

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

  14. REMOVE TIMING GEAR COVER INSULATOR


    1. A01E2IH

      Remove the bolt and timing gear cover insulator.

  15. REMOVE VACUUM PUMP ASSEMBLY


    1. Disconnect the vacuum hose.

    2. A01DVEJE01

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

  16. REMOVE VANE PUMP ASSEMBLY


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

      Tech Tips

      It is not necessary to remove the hose from the vane pump. For the remaining removal procedures, you may put the removed assembly aside in an appropriate location.

  17. 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
      09213-58013
      09330-00021

  18. 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.

  19. REMOVE CRANKSHAFT POSITION SENSOR


    1. Disconnect the sensor connector.

    2. Remove the 3 clips, bolt and sensor.

      A01DVCJ

  20. REMOVE CAMSHAFT POSITION SENSOR

    A01E329

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  21. REMOVE TIMING GEAR COVER


    1. Remove the wire harness clamp.

    2. A01DWDME01

      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.

  22. FIX NO. 1 IDLE GEAR


    1. A01DWNIE03
      Text in Illustration
      *1 Service Bolt

      Fix the sub idle gears to the idle gear with the service bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      If the screw hole position of the rear sub idle gear is incorrect, rotate the crankshaft counterclockwise to correct the hole position. Then install the service bolt.

      Tech Tips

      The service bolt is installed to eliminate torsional force caused by the idle gear springs, which are located between the idle gear and each sub idle gear. Torsional force will cause the sub idle gear's tooth and idle gear's tooth to be out of alignment.

  23. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DW5HE01

      Remove the No. 1 crankshaft position sensor plate.

    2. A01DYTAE01

      Using SST, remove the crankshaft timing gear.

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

  24. REMOVE NO. 1 IDLE GEAR


    1. A01DZB2E01

      Remove the 2 bolts, idle gear thrust plate.

    2. Remove the service bolt and idle gear.

    3. Remove the No. 1 idle gear shaft.

  25. REMOVE INJECTION GEAR


    1. A01DWERE01

      Using SST, remove the injection gear.

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

  26. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01DVYA

      Disconnect the 2 fuel hoses.

    2. A01DZOI

      Disconnect the 2 connectors.

    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. A01E0MBE02

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

      SST
      09213-58013
      09330-00021
    6. A01DXRJ

      Loosen the 2 nuts.

    7. 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.

    8. Remove the 2 nuts and pump.

      Note


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

      • The pump must be kept horizontal.

    9. Remove the O-ring.

  27. REMOVE OIL DIPSTICK GUIDE

    A01DZT2

    1. Remove the bolt and injection pipe clamp.

    2. Remove the bolt and guide.

    3. Remove the O-ring from the guide.

  28. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 22 bolts and 2 nuts.

    2. A01DXTOE04

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

      • Be careful not to damage the oil pan flange.

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

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

  29. REMOVE TIMING GEAR CASE ASSEMBLY

    A01E2UBE01

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

      Note

      Do not drop the oil pump rotor.

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

    3. Remove the oil pump gasket.