Oil Pump Assembly Replacement
Part 1:
Part 2:
Part 3:
Part 4:
Part 5:
Part 6:
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE ENGINE UNDER COVER RH
4. DRAIN ENGINE OIL
a. Install a new gasket after draining engine oil.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
5. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
6. REMOVE V BELT NO.1
7. REMOVE VANE PUMP V BELT
8. REMOVE ENGINE MOVING CONTROL ROD
9. REMOVE ENGINE MOUNTING STAY NO.2 RH
10. REMOVE GENERATOR BRACKET NO.2
11. REMOVE CRANKSHAFT PULLEY
12. REMOVE TIMING BELT NO.1 COVER
13. REMOVE TIMING BELT NO.2 COVER
14. REMOVE TIMING BELT GUIDE NO.2
15. REMOVE TIMING BELT
16. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
17. REMOVE EXHAUST PIPE ASSY FRONT
18. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
19. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the 2 bolts, nut and drive belt adjusting bar bracket.
b. Remove the 2 nuts, the generator bracket adjusting bar with wire harness clamp bracket.
c. Disconnect the compressor, magnetic clutch connector and the wire harness clamp.
d. Remove the 3 bolts, the compressor and magnetic clutch.
HINT: Hang up the hoses instead of detaching.
20. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
21. REMOVE CAMSHAFT TIMING PULLEY
22. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm socket hexagon wrench, remove the timing belt idler and the plate washer.
23. REMOVE CRANKSHAFT TIMING PULLEY
24. REMOVE TIMING BELT NO.3 COVER
25. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
a. Remove the 2 bolts and compressor mounting bracket No. 1.
26. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt and oil level gage guide.
27. SEPARATE ENGINE MOUNTING INSULATOR FR
a. Remove the 3 nuts and a bolt, and separate the engine mounting insulator.
NOTICE: Do not remove the engine mounting insulator.
28. REMOVE ENGINE MOUNTING INSULATOR RH
a. Remove the bolt and disconnect the power steering return hose clamp from the frame.
b. Remove the 4 nuts.
c. Place a wooden block between the jack and engine, and set the jack, then remove the engine mounting insulator.
d. Handle a jack up to remove the engine mounting insulator RH.
NOTICE: Be careful not to damage the contact surfaces of the oil pan.
29. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts, nut and bracket.
30. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the 10 bolts and 2 nuts.
b. Using SST, remove the oil pan No. 2.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan No. 2 flange.
31. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt, 2 nuts and oil strainer sub-assembly.
32. REMOVE OIL PAN SUB-ASSY
a. Uniformly loosen the 17 bolts and 2 nuts. Remove the bolts and nuts.
b. Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
33. REMOVE CRANK POSITION SENSOR
a. Disconnect the crank position sensor connector.
b. Remove the bolt and crank position sensor.
34. REMOVE OIL PUMP ASSY
a. Remove the 9 bolts, O-ring and oil pump.
35. INSTALL OIL PUMP ASSY
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010
NOTICE:
- Be careful not to tap the oil seal at an angle.
- Keep the gap between oil pump body edge and oil seal free from contamination.
b. Apply a small amount of MP grease to the oil seal lip.
c. Remove any old seal packing material from the contact surface.
d. Apply engine oil to a new O-ring and place it on the cylinder block.
e. Apply seal packing to the oil pump assembly as shown in the illustration.
Seal packing: Part No. 08226-00080 or equivalent.
NOTICE:
^ Install the oil pump assembly within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.
f. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
g. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head 8 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
14 mm head 43 Nm (439 kgf-cm, 32 ft. lbs.)
36. INSTALL CRANK POSITION SENSOR
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
37. INSTALL OIL PAN SUB-ASSY
a. Remove any old seal packing from contact surface.
b. Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08226-00080 or equivalent.
NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt hole in the region "X".
^ Apply seal packing to the inner side of the bolt hole in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.
c. Install the oil pan with the 17 bolts and 2 nuts.
Torque:
10 mm head 8 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (204 kgf-cm, 15 ft. lbs.)
14 mm head 37 Nm (379 kgf-cm, 27 ft. lbs)
d. Install the flywheel housing under cover with the two bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in. lbs.)
38. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
39. INSTALL OIL PAN SUB-ASSY NO.2
a. Remove any old seal packing from contact surface.
b. Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08226-00080 or equivalent.
NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.
c. Install oil pan with the 10 bolts and 2 nuts.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
40. INSTALL ENGINE MOUNTING BRACKET RH
Torque:
Bolt A 54 Nm (550 kgf-cm, 40 ft. lbs.)
Nut B 54 Nm (550 kgf-cm, 40 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
41. INSTALL ENGINE MOUNTING INSULATOR RH
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (887 kgf-cm, 64 ft. lbs.)
42. INSTALL ENGINE MOUNTING INSULATOR FR
Torque:
Bolt A 87 Nm (887 kgf-cm, 64 ft. lbs.)
Nut B 52 Nm (531 kgf-cm, 38 ft. lbs.)
43. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring, bolt and oil level gage guide.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
44. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
45. INSTALL TIMING BELT NO.3 COVER
46. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
47. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
48. INSTALL CAMSHAFT TIMING PULLEY
49. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
50. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
51. INSTALL EXHAUST PIPE ASSY FRONT
52. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
53. INSPECT TIMING BELT
54. INSTALL TIMING BELT
55. INSTALL TIMING BELT GUIDE NO.2
56. INSTALL TIMING BELT NO.2 COVER
57. INSTALL TIMING BELT NO.1 COVER
58. INSTALL CRANKSHAFT PULLEY
59. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 inch lbs.)
60. INSTALL ENGINE MOUNTING STAY NO.2 RH
61. INSTALL ENGINE MOVING CONTROL ROD
62. INSTALL VANE PUMP V BELT
63. INSTALL V BELT NO.1
64. INSPECT DRIVE BELT TENSION
65. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
66. ADD ENGINE OIL
67. INSPECT OIL LEAK
68. INSTALL FRONT WHEEL RH
69. CHECK EXHAUST GAS LEAK