GSIC - Global Service Information Center

# OIL PUMP > REMOVAL

## for Preparation Click here

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

  Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

1. Remove the 4 bolts and under cover.

3. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)

1. Remove the 2 bolts and under cover.

4. DRAIN ENGINE OIL

5. DRAIN TRANSMISSION OIL (for Manual Transmission)

1. Stop the vehicle on a level surface.

1. Remove the filer plug and gasket.

1. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
   If the result is not as specified, add transmission oil.

   Oil grade:
     GL-4 or GL-5

   Viscosity:
     SAE 75W-90

   Capacity:
     2.6 liters (2.7 US qts, 2.3 lmp.qts)

   NOTICE:
   1. Too much or too little oil will lead to transmission problems.
   2. After adjusting the oil level, drive the vehicle and check the oil level again.

1. Check for oil leakage when the oil level is low.
   If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.

1. Install a new gasket and the filler plug.

   Torque:
     37 N*m{ 377 kgf*cm , 27 ft.*lbf }

6. DRAIN TRANSMISSION FLUID (for Automatic Transmission)

HINT:

  Drive the vehicle so that the engine and transmission are at normal operating temperature.

ATF temperature:
  70 to 80° C (158 to 176° F)

1. Park the vehicle on a level surface and set the parking brake.

1. With the engine idling and the brake pedal depressed, move the shift lever into all positions from P to L. Then return it to P.

1. Pull out the dipstick and wipe it clean.

1. Push it back fully into the pipe.

1. Pull it out and check that the fluid level is in the HOT range.
   If there are leaks, it is necessary to repair or replace O-rings, FIPG, oil seals, plugs or other parts.

7. DRAIN ENGINE COOLANT

NOTICE:

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

1. 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.

8. LOOSEN FUEL TANK CAP ASSEMBLY

9. DRAIN FUEL

10. REMOVE HOOD SUB-ASSEMBLY

1. Disconnect the washer nozzle hose from the washer nozzle.

1. Remove the 4 bolts and hood.

11. REMOVE RADIATOR GRILLE

1. Using a clip remover, remove the 2 clips.

1. Remove the 2 screws.

1. Pull the radiator grille in the direction indicated by the arrow in the illustration to detach the 5 claws and remove the radiator grille.

12. REMOVE BATTERY BRACKET

13. REMOVE BATTERY AND BATTERY TRAY

14. REMOVE AIR CLEANER ASSEMBLY

1. Disconnect the MAF meter connector and remove the clamp.

1. Loosen the hose clamp of the compressor inlet elbow.

1. Remove the 2 bolts and air cleaner.

15. REMOVE RADIATOR ASSEMBLY

1. Remove the radiator assembly (Click here).

16. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

1. Remove the 3 bolts, 2 nuts and cover.

17. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

1. Disconnect the diesel turbo IAT sensor connector.

1. Loosen the 2 hose clamps of the No. 1 air hose.

1. Loosen the 2 hose clamps of the No. 2 air hose.

1. Remove the 4 bolts and CAC.

1. Using a 22 mm deep socket wrench, remove the IAT sensor.

   HINT:
     Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

1. Remove the 4 bolts, intake air connector and gasket.

18. DISCONNECT HOSES AND CONNECTORS

1. Remove the engine room relay block cover (upper).

1. Remove the No. 1 engine room relay block cover (side).

1. Remove the nut and disconnect the engine room J/B wire.

1. Disconnect the 2 engine room junction block connectors.

1. Remove the bolt and disconnect the ground cable.

1. Disconnect the 2 injector driver connectors.

1. Disconnect the 4WD control ECU connector.

1. Disconnect the turbo motor driver connector.

1. Disconnect the 3 TCM connectors.

1. Disconnect the 4 ECM connectors.

1. Disconnect the 2 fuel hoses.

1. Disconnect the vacuum pump hose.

1. Disconnect the oil reservoir to pump hose.

1. Using SST, disconnect the pressure feed tube.

   SST
     09023-12701

19. REMOVE COOLER COMPRESSOR ASSEMBLY

1. Remove the 4 bolts and disconnect the cooler compressor.

   HINT:
     It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

20. REMOVE STARTER ASSEMBLY

1. Disconnect the starter connector.

1. Remove the nut and disconnect the starter wire.

1. A/T:
   Remove the 2 bolts and A/T dipstick.

1. M/T:
   Remove the clutch release cylinder.

1. A/T:
   Remove the 2 nuts, bolt, ground cable and starter.

1. M/T:
   Remove the nut, bolt, ground cable and starter.

21. REMOVE FRONT EXHAUST PIPE ASSEMBLY

1. Remove the 2 bolts and 2 compression springs.

1. Disconnect the front pipe from the outlet pipe and remove the gasket.

1. Remove the front pipe from the pipe support.

22. REMOVE PROPELLER SHAFT ASSEMBLY

1. Front Side:
   Remove the propeller shaft assembly (Click here).

1. Rear Side:
   Remove the propeller shaft assembly (Click here).

23. REMOVE TRANSMISSION ASSEMBLY

1. Manual Transmission:
   Remove the transmission assembly (Click here).

1. Automatic Transmission:
   Remove the transmission assembly (Click here).

24. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

1. Remove the 8 bolts and flywheel.

25. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

1. Remove the 8 bolts, drive plate spacer, drive plate ring gear.

26. REMOVE REAR END PLATE

1. Remove the bolt and end plate.

27. REMOVE ENGINE ASSEMBLY

1. Set the No. 1 engine hanger and No. 2 engine hanger to the locations shown in the illustration.

   Torque:
     25 N*m{ 255 kgf*cm , 18 ft.*lbf } for No. 1 engine hanger
     68 N*m{ 693 kgf*cm , 50 ft.*lbf } for No. 2 engine hanger

   Engine Hanger Part No.:

     Parts Name | Parts No.
     Engine hanger No. 1 | 12284-30020
     Bolt (91512-61014)
     Engine hanger No. 2 | 12282-67020
     Bolt (91642-81030)

   NOTICE:
     Install the engine hangers with new bolts.

1. Hold the engine with the engine sling device and chain block.

1. Remove the 4 bolts and 4 nuts.

1. Remove the engine by operating the engine sling device and chain block.

28. FIX ENGINE ON ENGINE STAND

29. REMOVE NO. 1 TIMING BELT COVER

1. Remove the bolt and water hose clamp.

1. Remove the wire harness clamp.

1. Remove the 6 bolts and timing belt cover.

30. REMOVE TIMING BELT

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

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

1. Remove the timing belt.

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

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

31. REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY

32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. Remove the 4 bolts and belt tensioner.

33. REMOVE GENERATOR BRACKET

34. REMOVE GENERATOR ASSEMBLY

1. Remove the nut and generator wire.

1. Disconnect the generator connector.

1. Remove the 2 bolts, adjusting bar and generator.

35. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

1. Remove the 4 bolts and mounting bracket.

36. REMOVE MANIFOLD STAY

1. Remove the 2 bolts and stay.

37. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

1. Remove the bolt and clamp.

1. Remove the 2 bolts and oil level gauge guide.

1. Using SST, loosen the union nuts and remove the fuel inlet pipe.

   SST
     09023-12701

38. REMOVE INJECTION PIPE

NOTICE:

1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

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

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

1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

   SST
     09023-12701

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

   2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
        09023-12701

39. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

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

40. REMOVE CAMSHAFT TIMING PULLEY

1. 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.

1. Remove the camshaft timing pulley.

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

42. REMOVE NO. 2 TIMING BELT COVER

1. Remove the 4 bolts, nuts and timing belt cover.

43. REMOVE WATER PUMP ASSEMBLY

1. Remove the 2 nuts, 6 bolts, water pump and gasket.

44. REMOVE VACUUM PUMP ASSEMBLY

1. Remove the vacuum hose.

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

45. REMOVE VANE PUMP ASSEMBLY

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

   HINT:
     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.

46. REMOVE PUMP DRIVE SHAFT PULLEY

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

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

   SST
     09213-58013
     09330-00021

47. REMOVE CRANKSHAFT PULLEY

1. Using SST, remove the pulley bolt.

   SST
     09213-58013
     09330-00021

1. Using SST, remove the pulley.

   SST
     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 to using it.

48. REMOVE CAMSHAFT POSITION SENSOR

1. Remove the bolt and sensor.

1. Remove the O-ring from the sensor.

49. REMOVE CRANKSHAFT POSITION SENSOR

1. Remove the bolt and sensor.

1. Remove the O-ring from the sensor.

50. REMOVE TIMING GEAR COVER

1. Remove the wire harness clamp.

1. Remove the 14 bolts and 2 nuts.

1. 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.

1. Remove the cover and O-ring.

51. FIX NO. 1 IDLE GEAR

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

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

   NOTICE:
     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.

   HINT:
     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.

52. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

1. Remove the No. 1 crankshaft sensor plate.

1. Install the service bolt to the crankshaft.

1. Using SST, remove the crankshaft timing gear.

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

53. REMOVE NO. 1 IDLE GEAR

1. Remove the 2 bolts, idle gear thrust plate and idle gear.

1. Remove the No. 1 idle gear shaft.

54. REMOVE INJECTION GEAR

1. Using SST, remove the injection gear.

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

55. REMOVE FUEL SUPPLY PUMP ASSEMBLY

1. Remove the bolt and clamp.

1. Remove the 2 bolts and oil level gauge guide.

1. Using SST, loosen the union nuts and remove the fuel inlet pipe.

   SST
     09023-12701

1. Disconnect the 2 fuel hoses.

1. Disconnect the 2 connectors.

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

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

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

   SST
     09213-58013
     09330-00021

1. Loosen the 2 nuts.

1. 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.

1. Remove the 2 nuts and pump.

   NOTICE:
   1. Do not hold the pump or carry it holding the pipe.
   2. The pump must be kept horizontal.

1. Remove the O-ring.

56. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

1. Remove the bolt and oil level gauge.

1. Remove the O-ring from the oil level gauge.

57. REMOVE OIL PAN SUB-ASSEMBLY

1. Remove the 22 bolts and 2 nuts.

1. Insert the blade of SST between the cylinder block and oil pan. Cut through the applied sealer and remove the oil pan.

   SST
     09032-00100

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

1. Remove the oil pan gasket.

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

58. REMOVE TIMING GEAR CASE ASSEMBLY

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

   NOTICE:
     Do not drop the oil pump rotor.