Removal and Installation
Part 1:
Part 2:
Part 3:
Part 4:
Part 5:
Part 6:
OIL PUMP ASSY
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE OIL
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER NO.1
5. REMOVE ENGINE UNDER COVER NO.2
6. REMOVE FRONT FENDER APRON SEAL RH
7. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
8. REMOVE GENERATOR ASSY
9. REMOVE VANE PUMP V BELT
10. REMOVE ENGINE MOVING CONTROL ROD
11. REMOVE ENGINE MOUNTING STAY NO.2 RH
12. REMOVE GENERATOR BRACKET NO.2
13. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
14. REMOVE TIMING BELT NO.1 COVER
15. REMOVE TIMING BELT NO.2 COVER
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE TIMING BELT GUIDE NO.2
18. REMOVE TIMING BELT (See page 14-79)
19. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
20. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
21. REMOVE TIMING BELT NO.3 COVER
22. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
23. REMOVE CRANKSHAFT TIMING PULLEY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
24. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
25. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
26. REMOVE EXHAUST PIPE ASSY FRONT
27. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
28. REMOVE OIL LEVEL GAGE GUIDE
29. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts and 2 nuts, then remove the adjusting bar.
30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt and nut, then remove the adjusting bar bracket.
b. Remove the 3 bolts and compressor.
HINT: Secure the hoses off to the side instead of detaching.
31. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
a. Remove the 2 bolts and compressor mounting bracket.
32. SEPARATE ENGINE MOUNTING INSULATOR FR
a. Remove the 3 nuts and bolt, then separate the engine mounting insulator FR.
NOTICE: Do not remove the engine mounting insulator FR.
33. REMOVE ENGINE MOUNTING INSULATOR RH
a. Remove the bolt, then disconnect the power steering return hose clamp from the frame.
b. Remove the 4 nuts.
c. Place a wooden block on a jack underneath the engine.
d. Jack up the engine, then remove the engine mounting insulator RH.
NOTICE: Be careful not to damage the oil pan.
34. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and nut, then remove the bracket.
35. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the 10 bolts and 2 nuts.
b. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, then cut off the sealer and remove the oil pan No. 2.
SST 09032-00100
NOTICE:
^ Be careful not to damage the contact surface of the oil pan No. 1 where the oil pan No. 2 is mounted.
^ Do not damage the flange portion of the oil pan No. 2 when removing.
36. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
37. REMOVE OIL PAN SUB-ASSY
a. Remove the 2 bolts and nut, then disconnect the engine oil level sensor connector.
b. Remove the 2 bolts and flywheel housing under cover.
c. Loosen and remove the 17 bolts and 2 nuts uniformly.
d. Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
38. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector.
b. Remove the bolt and crankshaft position sensor.
39. REMOVE OIL PUMP ASSY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
c. Remove the O-ring.
40. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in the 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 lip free of foreign objects.
b. Apply multi-purpose grease to the oil seal lip.
41. INSTALL OIL PUMP ASSY
a. Remove any old seal packing material from the contact surface.
b. Apply a light coat of engine oil to a new O-ring, then place it on the cylinder block.
c. 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. 08826-00080 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 packing to engine oil within 2 hours after installing.
d. Align the key of the oil pump drive gear with the keyway located on the crankshaft, then slide the oil pump into place.
e. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt A
20 Nm (199 kgf-cm, 14 ft. lbs.) for bolt B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
42. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
43. 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 packing to engine oil within 2 hours after installing.
c. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for 10 mm head
20 Nm (199 kgf-cm, 14 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.)
e. Install the engine oil level sensor connector with the 2 bolts and nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
14. 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.)
45. 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 packing to engine oil within 2 hours after installing.
c. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
46. INSTALL ENGINE MOUNTING BRACKET RH
Torque:
54 Nm (551 kgf-cm, 40 ft. lbs.) for bolt A
54 Nm (551 kgf-cm, 40 ft. lbs.) for nut B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
47. 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
48. INSTALL ENGINE MOUNTING INSULATOR FR
Torque:
87 Nm (887 kgf-cm, 64 ft. lbs.) for bolt A
52 Nm (530 kgf-cm, 38 ft. lbs.) for nut B
49. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
50. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
25 Nm (250 kgf-cm, 18 ft. lbs.) for bolt
26 Nm (260 kgf-cm, 19 ft. lbs.) for nut
51. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for nut A
18 Nm (184 kgf-cm, 13 ft. lbs.) for bolt B
8.4 Nm (85 kgf-cm, 74 inch lbs.) for bolt C
52. INSTALL OIL LEVEL GAGE GUIDE
53. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
54. INSTALL EXHAUST PIPE ASSY FRONT
55. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
56. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
57. INSTALL CRANKSHAFT TIMING PULLEY
58. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
59. INSTALL TIMING BELT NO.3 COVER (See page 14-93)
60. INSTALL CAMSHAFT TIMING PULLEY (See page 14-93)
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
61. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
62. INSPECT TIMING BELT
63. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
64. INSTALL TIMING BELT TENSIONER ASSY
65. INSTALL TIMING BELT GUIDE NO.2
66. INSTALL ENGINE MOUNTING BRACKET RH
67. INSTALL TIMING BELT NO.2 COVER
68. INSTALL TIMING BELT NO.1 COVER
69. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
70. INSTALL GENERATOR BRACKET NO.2
71. INSTALL ENGINE MOUNTING STAY NO.2 RH
72. INSTALL ENGINE MOVING CONTROL ROD
73. INSTALL VANE PUMP V BELT
74. INSTALL GENERATOR ASSY
75. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
76. INSPECT DRIVE BELT DEFLECTION AND TENSION
77. INSTALL FRONT WHEEL RH
78. ADD ENGINE OIL
79. CHECK FOR ENGINE OIL LEAKS
80. CHECK FOR EXHAUST GAS LEAKS
81. SYSTEM INITIALIZATION