Oil Pump (W/O Dpf) Removal

Remove the oil filler cap.

Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

Wipe the oil pan and drain plug.

Install a new gasket and the oil pan drain plug.

Torque:

34 N*m{347 kgf*cm, 25 ft.*lbf}

Loosen the radiator drain cock plug.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Drain the coolant by removing the radiator reservoir cap and, using a wrench, remove the vent plug.

Loosen the cylinder block drain cock plug.

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

Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

HINT:

If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.

Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.

Remove the timing belt.

HINT:

1. If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
2. When installing the timing belt, turn the camshaft to align the timing marks, and then turn the crankshaft clockwise to align the timing marks.
   

Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.

Remove the bolt, pulley plate, No. 2 idle pulley and spacer.

Remove the nut and generator wire.

Disconnect the generator connector.

Remove the 2 bolts and generator.

Remove the bolt and generator bracket.

Remove the 4 bolts and V-ribbed belt tensioner.

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

Disconnect the 2 connectors.

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

Disconnect the 2 vacuum switching valve connectors and the 3 vacuum transmitting hoses.

Remove the 2 bolts and manifold stay with vacuum switching valve.

Remove the 2 bolts and manifold stay.

Remove the clamp.

Disconnect the No. 3 water by-pass hose from the EGR cooler.

Disconnect the No. 4 water by-pass hose from the EGR cooler.

w/ EGR Cooler:

1. Remove the 2 nuts and No. 3 injection pipe clamp.
   





2. Remove the 2 bolts and 2 No. 2 injection pipe clamps.
   





3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
   

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

w/o EGR Cooler:

1. Remove the bolt and No. 2 injection pipe clamp.
   

   Text in Illustration

   *1	No. 2 Injection Pipe Clamp
   *2	No. 3 Injection Pipe Clamp
   *a	Injector Side
   *b	Common Rail Side

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 the 3 bolts and No. 2 intake air connector bracket.

w/ EGR Cooler:

1. Disconnect the 2 connectors.
   





2. Disconnect the 5 vacuum hoses.
   

3. Remove the bolt and No. 1 gas filter with the gas filter bracket.
   





4. Remove the 2 bolts and electric vacuum regulating valve bracket together with the vacuum damper.
   

   NOTICE:

   Do not remove the electric vacuum regulating valve from the bracket.

w/o EGR Cooler:

1. Disconnect the connector.
   

2. Disconnect the 2 vacuum hoses.
   

3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.
   

   NOTICE:

   Do not remove the electric vacuum regulating valve from the bracket.

Remove the 3 nuts, No. 2 intake air connector and gasket.

Remove the 3 nuts, No. 2 intake air connector and gasket.

Disconnect the vacuum hose from the No. 2 EGR valve.

Remove the bolt, 2 nuts, electric EGR control valve with No. 2 EGR valve and EGR cooler.

Remove the gasket from the cylinder head.

w/ EGR Cooler:

1. Remove the bolt and disconnect the injection pipe clamp.
   





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

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

w/o EGR Cooler:

1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.
   





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

   Text in Illustration

   *a	Injector Side
   *b	Common Rail Side

Remove the engine oil level dipstick.

Remove the bolt and injection pipe clamp.

Remove the bolt and engine oil level dipstick guide.

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

Remove the engine oil level dipstick.

Remove the bolt and injection pipe clamp.

Remove the bolt and engine oil level dipstick guide.

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

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

Disconnect the 3 fuel hoses.

Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

w/ EGR Cooler:
Remove the 3 bolts and disconnect the 4 injector connectors.

w/o EGR Cooler:
Disconnect the 4 injector connectors.

Disconnect the ventilation hose.

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

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

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

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

NOTICE:

Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

Remove the camshaft timing pulley.

Remove the 4 bolts, nut and timing belt cover.

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

Remove the bolt and timing gear cover insulator.

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

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

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor.

Disconnect the crankshaft position sensor connector.

Remove the 4 clips, bolt and crankshaft position sensor.

Remove the 4 bolts, No. 2 camshaft timing pulley flange and pump drive shaft pulley.

Using SST, hold the crankshaft pulley and remove the nut and O-ring.

SST

09213-58014
09330-00021

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

SST

09213-58014
09330-00021

Using SST, remove the pulley bolt and crankshaft pulley.

SST

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

Remove the 14 bolts and 2 nuts.

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

NOTICE:

Be careful not to drop the injection gear.

Remove the O-ring from the timing gear case.

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}

NOTICE:

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.

Remove the injection gear.

Remove the No. 1 crankshaft position sensor plate.

Using SST, remove the crankshaft timing gear.

SST

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

Remove the 2 bolts and idle gear thrust plate.

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

Remove the No. 1 idle gear shaft.

Disconnect the 2 fuel hoses.

Disconnect the fuel temperature sensor connector and suction control valve connector.

Remove the 4 bolts indicated by the arrows in the illustration.

Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

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

SST

09213-58014
09330-00021

Loosen the 2 nuts.

Using SST, disconnect the fuel supply pump from the injection gear.

SST

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

NOTICE:

Apply lubricant to the threads and tip of SST (center bolt) before using it.

Remove the 2 nuts and fuel supply pump.

NOTICE:

1. Do not hold or carry the fuel supply pump by the pipe.
   
2. The fuel supply pump must be kept horizontal.
   

Remove the O-ring.

Remove the 22 bolts and 2 nuts.

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

NOTICE:

1. Do not use the oil pan seal cutter for the area between the oil pan and timing belt case, or for the area between the oil pan and rear oil seal retainer.
   
2. Be careful not to damage the oil pan flange.
   

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

Remove the bolt and No. 1 vacuum transmitting pipe.

Remove the union bolt and 8 bolts.

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

Remove the 2 O-rings.