Oil Pump and/or Oil Seal Replacement On-Car Service
1. Disconnect the battery ground cable.2. Remove the power steering pump drive belt (for vehicles with air conditioners, power steering pump and compressor drive belt). Loosen the two power steering pump adjust plate bolts.
3. Remove the alternator drive belt. The belt can be easily removed from the crank pulley side.
4. Disconnect the clip securing the high pressure air conditioning line to the strut tower.
5. Remove the timing belt upper cover.
6. Support the engine by using an engine hoist.
7. Disconnect the torque rod at the firewall.
8. Remove the passenger side engine mounting bracket from the engine.
9. Dust Cover Remove the flywheel dust cover.
v10. Use special tool No. J-37988 and J-38209, and remove the crank pulley bolt. To prevent the crankshaft pulley from rotating, insert a driver into a flywheel hole.
Crankshaft Pulley Bolt : J-37988
Extension Wrench : J-38209
11. Raise the passenger side of the engine, using engine hoist. Note:
Ensure the front wheel remains on the ground while lifting the engine. Raising the engine too high will lift the front wheel off the ground and may cause damage to the drive shaft universal joint.
12. Remove the timing belt lower cover.
13. Remove the crank pulley and pull up through the engine compartment.
14. Reinstall the crank pulley bolt.
15. Align the crank pulley timing gear to TDC.
16. Loosen the tension pulley bolt 1/2 turn counter clockwise. Note:
If the pulley bolt is loosened more than a 1/2 turn, the pulley will swing too far out of adjustment and will be difficult to readjust.
17. Remove the timing belt.
v18. Oil Pan
Remove the oil pan by using the seal cutter to shear sealant off.
Seal Cutter : J-37228 Note:
The sealant is applied to entire fitting face of oil pan. Do not pry it or you may distort the sealing flange.
19. Oil Pump Assembly Remove the oil pump fixing bolts and the oil pump assembly. Carefully remove the sealing materials from both the oil pump and the cylinder body. Be very careful not to damage the cylinder body or the oil pump.
20. Oil Seal Remove the oil seal with a screwdriver.
v21. Oil Seal Install the new oil seal. Apply engine oil to the oil seal lip after installation. v Installer : J-35269
v22. Oil Pump Assembly Install the oil pump assembly.
Torque kg-m(ft.lbs.)
1.0 (7.2)
v 23. Oil Pan
1) Completely remove all residual sealant, lubricant and moisture from the connecting surfaces. The surfaces must be perfectly dry.
v 2) Apply a correct width bead of sealant (TB-1207C or
its equivalent) to the contact surfaces of the oil pan.
There must be no gaps in the bead.
3) The oil pan must be installed within 30 minutes after sealant application.
v 4) The engine must not be started within 30 minutes of
installing the oil pan.
5) Tighten the bolts and nuts to the specified torque.
Torque kg-m(ft.lbs.)
1.0 (7.2)
24. Align the camshaft pulley timing marks.
25. Lock the camshaft pulley in position by inserting a 6 mm bolt through the camshaft pulleys and into the cylinder head.
26. Align the crank pulley timing gear to TDC.
27. Install the timing belt. Note:
A) To ensure the belt is installed correctly the lettering must be able to be read while viewing it from the passenger side fender. vB) The belt must be installed in the following order.
1) Crankshaft timing gear
2) Water pump
3) Idle pulley
4) Exhaust camshaft pulley
5) Inlet camshaft pulley
6) Tensioner pulley Note:
There must be no slack in the belt after it has been installed. The teeth of the belt and the teeth of the pulley must be in perfect alignment.
28. Belt Tension Loosen the tensioner bolt and apply the spring force to the belt. Note:
When reusing a belt, do not tension the belt with more than the spring force applied. When a new belt is used, push the tension pulley in the direction of belt tension.
v 29. Fixing Torque (Tensioner Pulley)
Torque kg-m(ft.lbs.)
2.4 (17.35)
Note:
Keep the tension pulley from turning while fastening the fixing bolt in order to prevent excessively high low tension of the timing belt.
30. Rotate the crankshaft two turns normally and make sure that the notch of cylinder No. 1 matches the scale on the timing cover match as well as the mark on the cam pulley. If it does not match them, repeat the procedure from step 24 - 29.
31. Turn the crankshaft by 60~ normally and measure deflection of the belt as shown in the figure. Make sure that it is within the specified range. If the deflection is not within the specified values, repeat the procedures from step 28 - 30. Belt tension at 10 kg (22.05 lbs.)
Tension mm(in.)
New belt 7 - 8.5 (0.28 - 0.33)
Used belt 9 - 10.5 (0.35 - 0.41)
v32. Crankshaft Pulley
^ Attach the taper face to the belt.
v ^ Tighten the center bolt to the specified torque.
While using a driver to prevent the flywheel from rotating.
Torque kg-m(ft.lbs.)
17.0 (123.0)
Crankshaft Pulley Bolt Socket : J-37988, J-38209
Extension Wrench : J-38209
vWhen using special tools J-37988 and J-38209, follow the torque instructions "4XE1 crank pulley bolt torque" at the end of this procedure.
v 33. Dust Cover
Install the flywheel dust cover.
v34. Timing Belt Cover
Tighten the bolts (total 8) to specification, while paying attention to the bolt length.
Torque kg-m(ft.lbs.)
1.0 (7.2)
v 35. Engine Mounting Bracket
Install engine mounting bracket.
Torque kg-m(ft.lbs.)
4.1 (29.7)
v36. Engine Mount Bracket Attach the engine mount cushion to the body, then lower the engine hoist gradually, aligning the bracket with the engine mount cushion. Tighten the bolts to the specified torque.
Torque kg-m(ft.lbs.)
Body side 8.4 (60.7)
Engine side 4.1 (29.7)
v37. Torque Rod
Tighten the bolt to specification.
Torque kg-m(ft.lbs.)
5.8 (42.0)
v38. Alternator, Power Steering Pump Adjust the V-belt and A/C compressor belt tension.
Belt Tension kg-m(ft.lbs.)
41 +/- 10 (90 +/- 20)
Using a Borroughs drive belt tension gauge.