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 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

1. Remove the oil filler cap.

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

   NOTICE:
     Collect the oil in an oil disposal container.

5. DRAIN TRANSMISSION OIL

1. R151/R151F:
   Drain transmission oil (Click here).

1. G50/G55:
   Drain transmission oil (Click here).

6. 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.

7. LOOSEN FUEL TANK CAP ASSEMBLY

8. DRAIN FUEL

9. REMOVE HOOD SUB-ASSEMBLY

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

1. Remove the 4 bolts and hood.

10. 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.

11. REMOVE BATTERY BRACKET

12. REMOVE BATTERY AND BATTERY TRAY

13. REMOVE AIR CLEANER ASSEMBLY

14. REMOVE RADIATOR ASSEMBLY

1. Remove the clamp and disconnect the IAT connector.

1. Loosen the clamp of the turbocharger.

1. Slide the clamp and disconnect the ventilation hose.

1. Remove the 2 bolts and air cleaner.

15. 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 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

16. 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.

17. REMOVE STARTER ASSEMBLY

1. Disconnect the starter connector.

1. Remove the nut and disconnect the starter wire.

1. Remove the clutch release cylinder.

1. Remove the nut, bolt, ground cable and starter.

18. 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.

19. REMOVE PROPELLER SHAFT ASSEMBLY

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

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

20. REMOVE TRANSMISSION ASSEMBLY

1. R151/R151F:
   Remove the transmission assembly (Click here).

1. G50/G55:
   Remove the transmission assembly (Click here).

21. REMOVE FLYWHEEL SUB-ASSEMBLY

1. Using SST, hold the crankshaft.

   SST
     09213-58013
     09330-00021

1. Remove the 8 bolts and flywheel.

22. REMOVE REAR END PLATE

1. Remove the bolt and end plate.

23. 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.

24. FIX ENGINE ON ENGINE STAND

25. 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.

26. 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.

27. REMOVE NO. 1 TIMING BELT TENSIONER ASSEMBLY

28. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

29. REMOVE GENERATOR BRACKET

30. REMOVE GENERATOR ASSEMBLY

1. Remove the nut and generator wire.

1. Disconnect the generator connector.

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

31. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

1. Remove the 4 bolts and mounting bracket.

32. REMOVE MANIFOLD STAY

1. Remove the 2 bolts and stay.

33. 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

34. 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

35. 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.

36. 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.

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

38. REMOVE NO. 2 TIMING BELT COVER

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

39. REMOVE WATER PUMP ASSEMBLY

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

40. REMOVE VACUUM PUMP ASSEMBLY

1. Remove the vacuum hose.

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

41. 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.

42. 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

43. 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.

44. REMOVE CAMSHAFT POSITION SENSOR

1. Remove the bolt and sensor.

1. Remove the O-ring from the sensor.

45. REMOVE CRANKSHAFT POSITION SENSOR

1. Remove the bolt and sensor.

1. Remove the O-ring from the sensor.

46. 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.

47. REMOVE NO. 1 IDLE GEAR

1. Secure the idle gears to the idle gear with the service bolt.

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

1. Remove the 2 bolts and thrust plate.

1. Turn the sub gear and align the gear teeth of the idle main gear and sub gear.

1. Remove the idle gear and sub gear.

1. Remove the idle gear shaft.

48. 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)

49. REMOVE INJECTION GEAR

1. Using SST, remove the injection gear.

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

50. 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.

51. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

1. Remove the bolt and oil level gauge.

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

52. 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.

53. REMOVE TIMING GEAR CASE ASSEMBLY

1. Remove the union bolt and 8 bolts.

1. Pry the gear case in the location shown in the illustration, and remove the gear case, driven rotor and gasket.

1. Remove the 2 O-rings.

   NOTICE:
     Do not drop the oil pump rotor.