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.

REMOVE ENGINE ASSEMBLY

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REMOVE NO. 1 TIMING BELT COVER
1. Remove the bolt and water hose clamp.
2. Remove the wire harness clamp.
3. Remove the 6 bolts and timing belt cover.
REMOVE TIMING BELT
1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
2. 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
  
  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.
REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY
REMOVE NO. 2 IDLE PULLEY ASSEMBLY
REMOVE GENERATOR ASSEMBLY
1. Remove the nut and generator wire.
2. Disconnect the generator connector.
3. Remove the 2 bolts and generator.
REMOVE GENERATOR BRACKET
1. Remove the bolt and generator bracket.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
1. Remove the 4 bolts and V-ribbed belt tensioner.
REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET
1. Remove the 4 bolts and No. 1 compressor mounting bracket.
REMOVE MANIFOLD STAY
1. Remove the 2 bolts and stay.
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
1. Remove the engine oil level dipstick.
2. 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. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
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. 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.
REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY
1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.
  
  Note
  
  If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
2. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
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. Remove the 3 bolts and disconnect the 4 connectors.
2. Disconnect the ventilation hose.
3. Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.
4. Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
5. Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
REMOVE CAMSHAFT TIMING PULLEY
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.
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
REMOVE NO. 2 TIMING BELT COVER
1. Remove the 4 bolts, nuts and No. 2 timing belt cover.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 5 bolts, 2 nuts, water pump and gasket.
REMOVE VACUUM PUMP ASSEMBLY
1. Remove the 2 nuts, vacuum pump and 2 O-rings.
REMOVE VANE PUMP ASSEMBLY
1. Remove the 2 nuts, vane pump and O-ring.
REMOVE PUMP DRIVE SHAFT PULLEY
1. Remove the 4 bolts, No. 2 camshaft timing pulley flange and pump drive shaft pulley.
2. Using SST, hold the crankshaft pulley and remove the nut and O-ring.
  
  SST
  
  09213-58014
  
  09330-00021
REMOVE CRANKSHAFT PULLEY
1. Using SST, remove the pulley bolt.
  
  SST
  
  09213-58014
  
  09330-00021
2. 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.
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the bolt and camshaft position sensor.
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
REMOVE TIMING GEAR COVER
1. Remove the bolt and No. 1 vacuum transmitting pipe.
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.
FIX NO. 1 IDLE GEAR
1. Fix the sub idle gear to the idle gear with a service bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Note
  
  If the bolt hole of the sub idle gear is not aligned with the bolt hole of the idle gear, rotate the crankshaft counterclockwise to align the bolt holes. 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 sub idle gear. Torsional force will cause the sub idle gear's tooth and idle gear's tooth to be out of alignment.
REMOVE CRANKSHAFT TIMING GEAR
1. Remove the No. 1 crankshaft sensor plate.
2. Install a service bolt to the crankshaft.
3. Using SST, remove the crankshaft timing gear.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05010 )
REMOVE NO. 1 IDLE GEAR
1. Remove the 2 bolts and idle gear thrust plate, and then remove the idle gear together with the sub idle gear.
2. Remove the No. 1 idle gear shaft.
REMOVE INJECTION GEAR
1. Using SST, remove the injection gear.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
REMOVE FUEL SUPPLY PUMP ASSEMBLY
1. Remove the bolt and clamp.
2. Remove the 2 bolts and oil level gauge guide.
3. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
4. Disconnect the 2 fuel hoses.
5. Disconnect the 2 connectors.
6. 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. Remove the set nut and O-ring while holding the crankshaft pulley by using SST.
  
  SST
  
  09213-58013
  
  09330-00021
9. Loosen the 2 nuts.
10. 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.
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 22 bolts and 2 nuts.
2. 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.
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the 2 bolts, nut, oil strainer and gasket.
REMOVE TIMING GEAR CASE ASSEMBLY
1. Remove the 8 bolts and union bolt. Then remove the timing gear case, 2 O-rings and gasket.
  
  Note
  
  Do not drop the oil pump rotor.