Oil Pump Assembly Replacement
OIL PUMP ASSYREPLACEMENT
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 ENGINE MOUNTING BRACKET RH
15. REMOVE TIMING BELT GUIDE NO.2
16. REMOVE TIMING BELT
17. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
18. REMOVE EXHAUST PIPE ASSY FRONT
19. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
20. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a) Remove the 2 bolts, nut and drive belt adjusting bar bracket.
b) Remove the 2 nuts and generator bracket adjusting bar with the wire harness clamp bracket.
c) Disconnect the compressor, magnetic clutch connector and wire harness clamp.
d) Remove the 3 bolts, compressor and magnetic clutch.
HINT: Hang up the hoses instead of detaching.
21. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
22. REMOVE CAMSHAFT TIMING PULLEY
23. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a) Using a 10 mm socket hexagon wrench, remove the timing belt idler and plate washer.
24. REMOVE CRANKSHAFT TIMING PULLEY
25. REMOVE TIMING BELT NO.3 COVER
26. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
a) Remove the 2 bolts and mounting bracket.
27. REMOVE OIL LEVEL GAGE GUIDE
a) Remove the bolt and gage guide.
28. SEPARATE ENGINE MOUNTING INSULATOR FR
a) Remove the 3 nuts and bolt. Then separate the engine mounting insulator.
NOTICE: Do not remove the engine mounting insulator.
29. 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) Prepare a jack. Place a wooden block on the jack and set the jack under the engine. Remove the engine mounting insulator.
d) Raise the jack and lift up the engine. Then remove the engine mounting insulator RH.
NOTICE: Be careful not to damage the contact surfaces of the oil pan.
30. REMOVE ENGINE MOUNTING BRACKET RH
a) Remove the 4 bolts, nut and bracket.
31. REMOVE OIL PAN SUB-ASSY NO.2
a) Remove the 10 bolts, 2 nuts and oil pan.
b) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, cut through the sealer and remove oil pan No. 2.
SST 09032-00100
NOTICE:
^ Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
^ Do not damage the flange portion of oil pan No. 2 during removal.
32. REMOVE OIL STRAINER SUB-ASSY
a) Remove the bolt, 2 nuts, oil strainer and gasket.
33. REMOVE OIL PAN SUB-ASSY
a) Remove the 2 bolts and flywheel housing under cover.
b) Uniformly loosen the 17 bolts and 2 nuts. Remove the bolts and nuts.
c) Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan shown in the illustration.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
34. REMOVE CRANKSHAFT POSITION SENSOR
a) Disconnect the sensor connector.
b) Remove the bolt and sensor.
35. REMOVE OIL PUMP ASSY
a) Remove the 9 bolts.
b) Using a screwdriver, remove the oil pump by prying between the oil pump and main bearing cap.
c) Remove the O-ring.
36. INSTALL OIL PUMP ASSY
a) Using SST and a hammer, install a new oil seal. Tap the surface of the SST with the hammer until the oil seal's surface is flush with oil pump body edge.
SST 09223-00010
NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the 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 a light coat of engine oil to a new O-ring and place it on the cylinder block.
e) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08226-00080 or equivalent
NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pump.
f) Align the key of the oil pump drive gear with the key way located on the crankshaft, and slide the oil pump into place.
g) Install the oil pump by tightening the 9 bolts uniformly.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt A
20 Nm (203 kgf-cm, 15 ft. lbs.) for bolt B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
37. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
38. INSTALL OIL PAN SUB-ASSY
a) Remove any old seal packing from the contact surface.
b) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in the region "X".
^ Apply seal packing to the inner side of the bolt holes in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pan.
c) Install the oil pan No. 1 by tightening the oil pan's 17 bolts and 2 nuts uniformly.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) for 10 mm head
20 Nm (204 kgf-cm, 15 ft. lbs.) for 12 mm head
37 Nm (379 kgf-cm, 27 ft. lbs.) for 14 mm head
d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm. 69 inch lbs.)
39. INSTALL OIL STRAINER SUB-ASSY
a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
40. INSTALL OIL PAN SUB-ASSY NO.2
a) Remove any old seal packing from the contact surface.
b) Apply a continuous bead of seal packing (diameter: 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 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 expose the seal to engine oil for at least 2 hours after installing the oil pan.
c) Install the oil pan with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
41. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.) for bolt A
54 Nm (550 kgf-cm, 40 ft. lbs.) for nut B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
42. INSTALL ENGINE MOUNTING INSULATOR RH
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.) for nut A
87 Nm (887 kgf-cm, 64 ft. lbs.) for nut B
43. INSTALL ENGINE MOUNTING INSULATOR FR
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.) for bolt A
52 Nm (531 kgf-cm, 38 ft. lbs.) for nut B
44. INSTALL OIL LEVEL GAGE GUIDE
a) Install a new O-ring to the gage guide.
b) Install the gage guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
45. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
46. INSTALL TIMING BELT NO.3 COVER
47. 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.)
48. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
49. INSTALL CAMSHAFT TIMING PULLEY
50. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
51. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
52. INSTALL EXHAUST PIPE ASSY FRONT
53. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
54. INSPECT TIMING BELT
55. INSTALL TIMING BELT
56. INSTALL TIMING BELT TENSIONER ASSY
57. INSTALL TIMING BELT GUIDE NO.2
58. INSTALL ENGINE MOUNTING BRACKET RH
59. INSTALL TIMING BELT NO.2 COVER
60. INSTALL TIMING BELT NO.1 COVER
61. INSTALL CRANKSHAFT PULLEY
62. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 inch lbs.)
63. INSTALL ENGINE MOUNTING STAY NO.2 RH
64. INSTALL ENGINE MOVING CONTROL ROD
65. INSTALL VANE PUMP V BELT
66. INSTALL V BELT NO. 1
67. INSPECT DRIVE BELT TENSION
68. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
69. ADD ENGINE OIL
70. CHECK FOR ENGINE OIL LEAKS
71. INSTALL FRONT WHEEL RH
72. CHECK FOR EXHAUST GAS LEAKS