Removal and Installation

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER NO. 1
3. REMOVE FRONT FENDER APRON SEAL RH
4. DRAIN ENGINE OIL
a. Install a new gasket and the drain plug after draining engine oil.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
5. REMOVE EXHAUST PIPE ASSEMBLY FRONT
6. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET
7. REMOVE ENGINE MOUNTING STAY NO. 2 RH
8. REMOVE ENGINE MOUNTING BRACKET NO. 2 RH
9. REMOVE FAN AND GENERATOR V BELT
10. REMOVE ENGINE COVER SUB-ASSEMBLY NO. 1
11. DISCONNECT ENGINE WIRE
12. REMOVE GENERATOR ASSEMBLY
13. REMOVE VANE PUMP ASSEMBLY
14. REMOVE IGNITION COIL ASSEMBLY
15. DISCONNECT VENTILATION HOSE
16. DISCONNECT VENTILATION HOSE NO. 2
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
18. SET NO. 1 CYLINDER TO TDC/COMPRESSION
19. REMOVE CRANKSHAFT PULLEY
20. REMOVE CRANKSHAFT POSITION SENSOR

21. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 12 bolts and 2 nuts.

b. Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan.
SST 09032-00100

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

22. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1
23. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

24. INSTALL ENGINE HANGER NO. 1
a. Install the engine hanger No. 1 and No. 2.

25. REMOVE ENGINE MOUNTING INSULATOR
a. Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

b. Remove the bolt and disconnect the engine mounting insulator FR.

c. Remove the bolt and disconnect the steering gear return hose clamp from the frame.

d. Remove the 4 nuts from the engine mounting insulator RH.
e. Raise the engine and remove the engine mounting insulator RH.

26. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 3 bolts and engine mounting bracket.
27. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
28. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
29. REMOVE CHAIN TENSIONER SLIPPER
30. REMOVE CHAIN VIBRATION DAMPER NO. 1
31. REMOVE CHAIN SUB-ASSEMBLY
32. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

33. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise 90° and align the adjusting hole of the oil pump drive sprocket gear with the groove of the oil pump.

b. Insert a bar (4.0 mm (0.16 inch)) into the adjusting hole of the oil pump drive sprocket to temporarily lock the sprocket in position. Remove the nut.

c. Remove the bolt, chain tensioner plate and spring.
d. Remove the chain tensioner, oil pump drive sprocket and chain.

34. REMOVE OIL PUMP ASSEMBLY
a. Remove the 3 bolts, oil pump and gasket.

INSTALLATION

1. INSTALL OIL PUMP ASSEMBLY
a. Install a new gasket and oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

2. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
a. Set the crankshaft key in the horizontal left position.
b. Turn the cutout of the drive shaft to the top.

c. Align the mark links (yellow colored links) of the chain with the timing marks of the gear as shown in the illustration.
d. Insert the gear together with chain into the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear with the nut.

f. Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)

g. Align the adjusting hole of the sprocket with the groove of the oil pump.
h. Insert a bar (4 mm (0.16 inch)) into the adjusting hole of the sprocket to temporarily lock the gear in position. Install the nut.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

i. Rotate the crankshaft 90° clockwise and align the crankshaft key with the top.
3. INSTALL CRANKSHAFT TIMING SPROCKET
4. INSTALL CHAIN VIBRATION DAMPER
a. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
5. INSTALL CHAIN SUB-ASSEMBLY
6. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

9. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the engine mounting bracket with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

10. INSTALL ENGINE MOUNTING INSULATOR
a. Raise the engine and install the engine mounting insulator RH.
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.)

c. Install the steering gear return hose clamp to the frame with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

d. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
11. INSTALL OIL PAN SUB-ASSEMBLY

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
b. Apply seal packing in a continuous bead (Seal Width: 3.0 to 4.0 mm (0.12 to 0.16 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent

c. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
12. INSTALL CRANKSHAFT POSITION SENSOR
13. INSTALL CRANKSHAFT PULLEY
14. INSTALL CHAIN TENSIONER ASSEMBLY
15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
16. INSTALL IGNITION COIL ASSEMBLY
17. INSTALL VANE PUMP ASSEMBLY
18. INSTALL GENERATOR ASSEMBLY
19. INSTALL ENGINE WIRE
20. INSTALL FAN AND GENERATOR V BELT
21. REMOVE ENGINE MOUNTING BRACKET NO. 2 RH
22. INSTALL ENGINE MOUNTING STAY NO. 2 RH
23. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
24. INSTALL EXHAUST PIPE ASSEMBLY FRONT
25. INSTALL FRONT WHEEL RH
26. ADD ENGINE OIL
27. CHECK ENGINE OIL LEAKS