Oil Pump Assembly Replacement
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE FRONT FENDER APRON SEAL RH
5. DRAIN ENGINE OIL
a. Install a new gasket and the drain plug after draining engine oil.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
6. REMOVE EXHAUST PIPE ASSY FRONT
7. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET
a. Remove the 3 bolts and engine moving control rod w/ bracket.
8. REMOVE ENGINE MOUNTING STAY NO.2 RH
9. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
10. REMOVE FAN AND GENERATOR V BELT
11. REMOVE ENGINE COVER SUB-ASSY NO.1
12. DISCONNECT ENGINE WIRE
13. REMOVE GENERATOR ASSY
14. REMOVE VANE PUMP ASSY
NOTICE: Do not disconnect the hose.
15. REMOVE IGNITION COIL ASSY
16. DISCONNECT VENTILATION HOSE
17. DISCONNECT VENTILATION HOSE NO.2
18. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the bolt and disconnect the engine wire harness clamp.
b. Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover.
19. SET NO. 1 CYLINDER TO TDC/COMPRESSION
20. REMOVE CRANKSHAFT PULLEY
21. REMOVE CRANK POSITION SENSOR
22. REMOVE OIL PAN SUB-ASSY
a. Remove the 12 bolts and 2 nuts.
b. Insert the blade of SST between the crank case and oil pan, cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.
23. REMOVE CHAIN TENSIONER ASSY NO.1
24. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bolt, the bolt and drive belt tensioner.
25. REMOVE ENGINE HANGER NO.1
a. Install the engine hanger No.1, No.2 and bolt as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 30 ft. lbs.)
Parts No.: Engine hanger No. 1 12281-28010
Engine hanger No. 2 12282-28010
Bolt 91512-61020
26. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR
a. Attach the engine chain hoist to the engine hangers.
CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
b. Remove the bolt, and disconnect the engine mounting insulator.
c. Remove the bolt and disconnect the engine lateral control rod (M/T).
d. Remove the bolt and disconnect the steering gear return hose clamp from the frame.
e. Remove the 4 nuts from the engine mounting insulator RH.
f. Raise the engine and remove the engine mounting insulator RH.
27. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET RH
a. Remove the 3 bolts and the engine mounting bracket RH.
28. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
a. Remove the stud bolt for drive belt tensioner from the cylinder block.
b. Remove the 14 bolts and 2 nuts.
c. Remove the timing chain cover with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of timing chain cover, cylinder block and cylinder head.
29. REMOVE CRANKSHAFT POSITION SENSOR PLATE No.1
30. REMOVE CHAIN TENSIONER SLIPPER
31. REMOVE CHAIN VIBRATION DAMPER NO.1
32. REMOVE CHAIN SUB-ASSY
33. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
34. REMOVE NO.2 CHAIN SUB-ASSY
a. Turn the crankshaft counterclockwise 90°, and turn the cutout of the oil pump drive shaft gear to the top.
b. Align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
c. Put a bar ([diameter]4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut.
d. Remove the bolt, chain tensioner plate and spring.
e. Remove the chain tensioner, oil pump drive shaft gear and No.2 chain.
35. REMOVE OIL PUMP ASSY
a. Remove 3 bolts and oil pump assembly.
36. INSTALL OIL PUMP ASSY
a. Place a new gasket on the cylinder block.
b. Install the oil pump assembly with 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
37. INSTALL NO.2 CHAIN SUB-ASSY
a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.
c. Align the mark links (yellow colored links) with the timing marks of the gear as shown in the illustration.
d. Insert the gears with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear by a nut.
f. Inset the damper spring into the adjusting hole, and install the chain tensioner plate by a nut.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
g. Align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
h. Put a bar ([diameter]4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and assemble a nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)
i. Rotate the crankshaft clockwise 90°, and align the crankshaft key to the top.
38. INSTALL CHAIN VIBRATION DAMPER No.1
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
39. INSTALL CHAIN SUB-ASSY
a. Set No.1 cylinder to TDC/compression.
1. Align the timing marks of the camshaft timing sprockets and bearing caps (No.1 and No.2).
2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
b. Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing gear.
c. Using a SST, install the sprocket.
SST 09309-37010
d. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
40. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
41. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the crankshaft position sensor plate the "F" mark facing forward.
42. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
NOTICE:
^ Remove any oil from the contact surface.
^ Install the chain cover within 3 minutes after applying seal packing.
^ Do not start the engine 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b. Apply seal packing in the shape of bead (Diameter 2 mm (0.099 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.118 - 0.157 inch)) as shown in the illustration .
Seal packing: Part No. 08826-00080 or equivalent
d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B 21 Nm (214 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)
Nut 9.0 Nm (92 kgf-cm, 80 (inch lbs.)
e. Install the stud bolt to the drive belt tensioner.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
43. INSTALL CHAIN TENSIONER ASSY NO.1.
44. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the drive belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)
45. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
46. INSTALL ENGINE MOUNTING INSULATOR
a. Raise the engine and install the engine mounting insulator RH.
b. Install the engine mounting insulator RH with the 4 nuts.
Torque:
Bolt A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Bolt B 87 Nm (888 kgf-cm, 64 ft. lbs.)
c. Install the bolt and disconnect the steering gear return hose clamp from the frame.
Torque: 8.0 Nm (80 kgf-cm, 69 inch lbs.)
d. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)
e. Install the engine lateral control rod with the bolt (M/T).
Torque: 89 Nm (910 kgf-cm, 69 ft. lbs.)
47. INSTALL OIL PAN SUB-ASSY
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not start the engine 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan.
b. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.157 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
48. INSTALL CRANK POSITION SENSOR
a. Install the bolt and crankshaft position sensor.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Confirm the wire harness of the crank position sensor is placed as shown in the illustration.
49. INSTALL CRANKSHAFT PULLEY
a. Install the crankshaft pulley
b. Disconnect the plunger knock pin.
1) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
2) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
50. INSTALL CYLINDER HEAD COVER SUB-ASSY
51. INSTALL IGNITION COIL ASSY
Torque: 9.0 Nm (92 kg1-cm, 80 inch lbs.)
52. INSTALL VANE PUMP ASSY
53. INSTALL GENERATOR ASSY
54. INSTALL ENGINE WIRE
55. INSTALL FAN AND GENERATOR V BELT
56. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
57. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
58. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
a. Install the engine mounting control rod w/bracket with 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
59. INSTALL EXHAUST PIPE ASSY FRONT
60. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
61. ADD ENGINE OIL
62. INSPECT OIL LEAK