Oil Pump Removal

Remove the oil filler cap.

Remove the oil drain plug, and drain the engine oil from the oil pan.

NOTICE:

Collect the oil in an oil disposal container.

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

Loosen the cylinder block drain cock plug and the radiator drain cock plug.

HINT:

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

Remove the bolt and water hose clamp.

Remove the wire harness clamp.

Remove the 6 bolts and timing belt cover.

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

Uniformly loosen the 2 bolts and remove the timing belt tensioner.

Remove the timing belt.

Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

HINT:

1. 
   
2. When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
3. 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.
   

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

Disconnect the terminal cap.

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.

Remove the 2 bolts and stay.

Disconnect the 2 connectors.

Remove the 2 bolts, common rail and No. 2 intake manifold insulator.

NOTICE:

Do not remove the pressure discharge valve and fuel pressure sensor.

Remove the bolt and No. 2 injection pipe clamp.

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

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 bolt and No. 2 injection pipe clamp.

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

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 disconnect the 4 connectors.

Disconnect the ventilation hose.

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.

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

Remove the bolt of the camshaft timing pulley by 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 2 nuts, vacuum pump and 2 O-rings.

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

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, remove the pulley bolt.

SST

09213-58014
09330-00021

Using SST, remove the pulley.

SST

09213-58014
09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

NOTICE:

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

Remove the bolt and camshaft position sensor.

Remove the bolt and crankshaft position sensor.

Remove the bolt and No. 1 vacuum transmitting pipe.

Remove the 14 bolts and 2 nuts.

Using a slotted screwdriver, gently separate the cover from the timing gear case.

HINT:

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.

NOTICE:

Be careful not to damage the contact surfaces of the timing gear case and its cover.

Remove the cover and O-ring.

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

Torque:

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

NOTICE:

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.

HINT:

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 the No. 1 crankshaft sensor plate.

Install a service bolt to the crankshaft.

Using SST, remove the crankshaft timing gear.

SST

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

Remove the 2 bolts and idle gear thrust plate, and then remove the idle gear together with the sub idle gear.

Remove the No. 1 idle gear shaft.

Using SST, remove the injection gear.

SST

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

Remove the bolt and clamp.

Remove the bolt and oil dipstick guide.

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

Disconnect the 2 fuel hoses.

Disconnect the 2 connectors.

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

09213-58013
09330-00021

Loosen the 2 nuts.

Using SST, disconnect the 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 pump.

NOTICE:

1. Do not hold or carry the pump by holding the pipe.
   
2. The 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 cylinder block and oil pan. Cut through the applied sealer and remove the oil pan.

NOTICE:

1. Do not use the oil pan seal cutter for the timing gear case and rear oil seal retainer.
   
2. Be careful not to damage the oil pan flange.
   

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

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

NOTICE:

Do not drop the oil pump rotor.