OIL PUMP (w/o 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.


  1. REMOVE ENGINE ASSEMBLY

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  2. INSTALL ENGINE STAND

  3. REMOVE VANE PUMP ASSEMBLY


    1. B007QBUE01

      Remove the 2 nuts and the vane pump assembly.

    2. Remove the vane pump O-ring from the vane pump assembly.

  4. REMOVE TIMING GEAR COVER INSULATOR


    1. B007RND

      Remove the bolt and timing gear cover insulator.

  5. REMOVE VACUUM PUMP ASSEMBLY


    1. B007QFB

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

  6. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the wire harness clamp.

    2. B007QEM

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

  7. REMOVE TIMING BELT

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  8. REMOVE CRANKSHAFT POSITION SENSOR

    B007VEA

    1. Disconnect the crankshaft position sensor connector.

    2. Separate the connector from the No. 1 vacuum pipe .

    3. B007OTL

      Separate the 3 wire harness clamps.

    4. Remove the bolt and the crankshaft position sensor.

  9. REMOVE CAMSHAFT POSITION SENSOR

    B007VA3

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and the camshaft position sensor.

  10. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. w/o DPF:


      1. B007U29

        Disconnect the diesel turbo pressure sensor connector and vacuum switching valve connector.

      2. Remove the bolt and disconnect the wire harness clamp.

    2. Disconnect the 2 diesel throttle body connectors.

    3. B007TF0E01

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

  11. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  12. REMOVE EGR COOLER ASSEMBLY

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  13. REMOVE COMMON RAIL ASSEMBLY

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  14. REMOVE FUEL SUPPLY PUMP ASSEMBLY

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  15. REMOVE INJECTOR ASSEMBLY

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  16. REMOVE CAMSHAFT TIMING PULLEY


    1. B007SGO

      Remove the bolt and camshaft timing pulley while holding the camshaft with a wrench.

    2. B007RSCE01

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. B007R2IE02

      Rotate the crankshaft approximately 90° counterclockwise from TDC to lower the piston.

  17. REMOVE NO. 2 TIMING BELT COVER


    1. B007R1OE01

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

  18. REMOVE WATER PUMP ASSEMBLY


    1. B007V60

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

  19. REMOVE CRANKSHAFT PULLEY


    1. B007T0QE01

      Using SST, remove the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. B007R5AE01

      Using SST, remove the 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.

  20. REMOVE ENGINE OIL LEVEL SENSOR

    B007USY

    1. Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts and engine oil level sensor.

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. B007RQ5

      Disconnect the vinyl tube from the oil pan.

    2. B007P4QE02

      Remove the 22 bolts and 2 nuts.

    3. B007SVAE04

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block stiffening plate, cut through the applied sealer, and then remove the oil pan and cylinder block stiffening plate.

      Note


      • Do not use an oil pan seal cutter for the timing gear case side and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  22. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B007Q4W

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

  23. 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. B007TVX

      Remove the 14 bolts and 2 nuts.

    2. B007SFF

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

      Note

      Do not damage the contact surface.

    3. B007OTYE03

      Remove the O-ring from the timing gear case.

    4. B007QTI

      Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.

  24. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. B007RUS

      Using a screwdriver and hammer, tap out the oil seal.

  25. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. B007ORE

      Using a screwdriver and hammer, tap out the oil seal.

  26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B007SZ8E01

      Remove the No. 1 crankshaft position sensor plate.

  27. REMOVE INJECTION GEAR


    1. B007U8O

      Remove the injection gear.

  28. REMOVE CRANKSHAFT TIMING GEAR


    1. B007RCTE02

      Using SST, remove the crankshaft timing gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05011 )

  29. REMOVE IDLE GEAR THRUST PLATE


    1. B007UDN

      Remove the 2 bolts and idle gear thrust plate.

  30. REMOVE NO. 1 IDLE GEAR


    1. B007OET

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

      Note

      Make sure that the No. 2 idle sub gear and No. 1 idle gear are correctly fitted to each other.

  31. REMOVE NO. 1 IDLE GEAR SHAFT


    1. B007VAK

      Remove the No. 1 idle gear shaft.

  32. REMOVE TIMING GEAR CASE ASSEMBLY


    1. B007SP1

      Remove the union bolt and 8 bolts.

    2. B007U1SE02

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

      Note

      Do not drop the driven rotor.

    3. B007S1RE02

      Remove the gasket from the timing gear case.

    4. B007S3GE01

      Remove the driven rotor from the timing gear case.

    5. B007OYWE03

      Remove the 2 O-rings from the cylinder block.