Removal and Installation

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. REMOVE ENGINE UNDER COVER NO. 1
3. REMOVE FRONT FENDER APRON SEAL 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 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
6. REMOVE VANE PUMP V BELT
7. REMOVE ENGINE MOVING CONTROL ROD
8. REMOVE ENGINE MOUNTING STAY NO. 2 RH
9. REMOVE GENERATOR BRACKET NO. 2
10. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
11. REMOVE EXHAUST PIPE ASSEMBLY FRONT

12. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the 2 bolts, nut and drive belt adjusting bar bracket.

b. Remove the 2 nuts and the generator bracket adjusting bar together with the wire harness clamp bracket.
c. Disconnect the compressor, magnetic clutch connector and wire harness clamp.

13. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
a. Remove the 2 bolts and mounting bracket.
14. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
15. REMOVE OIL LEVEL GAGE GUIDE

16. REMOVE ENGINE MOUNTING
a. Remove the 4 nuts and bolt, and disconnect the engine mounting insulator FR.

NOTICE: Do not remove the engine mounting insulator.

b. Remove the 4 bolts, nut and engine mounting bracket RH.
17. REMOVE CRANKSHAFT PULLEY
18. REMOVE TIMING BELT NO. 1 COVER
19. REMOVE TIMING BELT NO. 2 COVER
20. REMOVE TIMING BELT GUIDE NO. 2
21. REMOVE TIMING BELT
22. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 1
a. Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer.
23. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 2
24. REMOVE CAMSHAFT TIMING PULLEY
25. REMOVE TIMING BELT NO. 3 COVER
26. REMOVE CRANKSHAFT TIMING PULLEY
27. REMOVE OIL PAN SUB-ASSEMBLY NO. 2
28. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts, then remove the oil strainer and the gasket.

29. REMOVE OIL PAN SUB-ASSEMBLY
a. Uniformly loosen and remove the 15 bolts and 2 nuts, as shown in the illustration.

b. Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.

NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.

30. REMOVE OIL PUMP ASSEMBLY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
c. Remove the O-ring.

INSTALLATION

1. INSTALL OIL PUMP ASSEMBLY
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 the 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 the 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 (seal width: 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:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (204 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)
2. INSTALL OIL PAN SUB-ASSEMBLY
3. INSTALL OIL STRAINER SUB-ASSEMBLY
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.)
4. INSTALL OIL PAN SUB-ASSEMBLY NO. 2
5. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
6. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
7. INSTALL OIL LEVEL GAGE GUIDE
8. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
9. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 1
a. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
10. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
11. INSTALL TIMING BELT NO. 3 COVER
12. INSTALL CAMSHAFT TIMING PULLEY
13. INSTALL TIMING BELT
14. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
15. INSTALL TIMING BELT GUIDE NO. 2
16. INSTALL TIMING BELT NO. 2 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Install the timing belt cover.
17. INSTALL TIMING BELT NO. 1 COVER

18. INSTALL ENGINE MOUNTING
a. Install the engine mounting bracket RH with the 4 bolts and nut.
Torque:
Bolt A 54 Nm (551 kgf-cm, 40 ft. lbs.)
Nut B 54 Nm (551 kgf-cm, 40 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)

b. Install the engine mounting insulator RH with the 4 nuts.
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (887 kgf-cm, 64 ft. lbs.)

HINT: First, loosely install the nut labeled (A) with your hand. Then use a wrench to install the 3 nuts labeled (B). Finally, use a wrench to tighten nut (A).

c. Install the engine mounting insulator FR with the nut.
Torque:
Nut A 87 Nm (887 kgf-cm, 64 ft. lbs.)
Nut B 52 Nm (530 kgf-cm, 38 ft. lbs.)
19. INSTALL CRANKSHAFT PULLEY
20. INSTALL GENERATOR BRACKET NO. 1
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
21. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
22. INSTALL ENGINE MOUNTING STAY NO. 2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

23. INSTALL ENGINE MOVING CONTROL ROD
a. Install the control rod and bracket with the 4 bolts.
Torque:
Bolt A 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 23 Nm (235 kgf-cm, 17 ft. lbs.)
24. INSTALL VANE PUMP V BELT
25. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
26. ADD ENGINE OIL
27. CHECK ENGINE OIL LEAKS