Removal and Installation
REPLACEMENT1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE ENGINE UNDER COVER NO.1
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 (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) 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
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
12. REMOVE TIMING BELT NO.1 COVER
13. REMOVE TIMING BELT NO.2 COVER
14. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
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, 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: Hung up the hoses instead of detaching.
21. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
22. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
23. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm socket hexagon wrench, remove the timing belt idler sub-assembly No.1 and the plate washer.
24. REMOVE CRANK SHAFT TIMING PULLEY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05010)
25. REMOVE TIMING BELT NO.3 COVER
26. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
a. Remove the 2 bolts and compressor mounting bracket No. 1.
27. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt and oil level gage guide.
28. SEPARATE ENGINE MOUNTING INSULATOR ASSY FRONT
a. Remove the 3 nuts and a bolt, and separate the engine mounting insulator front.
29. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR
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.
30. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
a. Remove the 4 bolts, nut and bracket.
31. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the 10 bolts and 2 nuts.
b. Using SST, remove the oil pan sub-assembly No. 2.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan No. 2 flange.
32. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt, 2 nuts and oil strainer sub-assembly.
33. REMOVE OIL PAN SUB-ASSY
a. Remove the 17 bolts and 2 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.
34. REMOVE CRANK POSITION SENSOR
a. Disconnect the crank position sensor connector.
b. Remove the bolt and crank position sensor.
35. REMOVE OIL PUMP ASSY
a. Remove the 9 bolts, O-ring and oil pump.
36. 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 slantingly.
b. Apply a small amount of MP grease to the oil seal lip.
NOTICE: Keep the lip off foreign materials.
c. Apply engine oil to the O-ring.
d. Install a new O-ring 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.)
37. INSTALL CRANK POSITION SENSOR
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
38. INSTALL OIL PAN SUB-ASSY
a. 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.
b. 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 (199 kgf-cm, 14 ft. lbs.)
39. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the bolt and
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
40. INSTALL OIL PAN SUB-ASSY NO.2
a. Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08226-00080 or equivalent.
NOTICE: Apply seal packing to the inner side of the bolt hole.
b. Install oil pan No. 2.
Torque: 8 Nm (82 kgf-cm,71 inch lbs.)
NOTICE:
^ Remove any oil from the contact surface.
^ Do not put into engine oil within 2 hours after installing.
41. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
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.)
42. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (887 kgf-cm, 64 ft. lbs.)
43. INSTALL ENGINE MOUNTING INSULATOR ASSY FRONT
Torque:
Bolt A 87 Nm (887 kgf-cm, 64 ft. lbs.)
Nut B 52 Nm (531 kgf-cm, 38 ft. lbs.)
44. 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.)
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
SST 09960-10010 (09962-01000, 09963-01000)
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
SST 09960-10010 (09962-01000, 09963-01000)
56. INSTALL CHAIN TENSIONER ASSY NO.1
57. INSTALL TIMING BELT GUIDE NO.2
58. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
59. INSTALL TIMING BELT NO.2 COVER
60. INSTALL TIMING BELT NO.1 COVER
61. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
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 (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
67. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
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. INSPECT OIL LEAK
71. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,051 kgf-cm, 76 ft. lbs.)
72. CHECK EXHAUST GAS LEAK