Repair Procedures
Oil And Filter Replacement
CAUTION:
- Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
- Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
- In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.
1. Drain the engine oil.
(1) Remove the oil filler cap.
(2) Remove the oil drain plug, and drain the oil into a container.
2. Replace the oil filter.
(1) Remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it an additional 3/4 turn.
3. Refill with engine oil.
(1) Clean and install the oil drain plug with a new gasket.
Tightening torque :
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
(2) Fill with fresh engine oil.
Capacity :
Total : 3.8L (4.02US qt, 3.34 lmp qt)
Oil pan : 3.0 L (3.17 US qts, 2.63 lmp qts)
Drain and refill including oil filter : 3.3 L (3.48 US qts, 2.90 lmp qts)
(3) Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.
Removal
Oil Pan
1. Drain the engine oil.
2. Disconnect the rear oxygen sensor connector(A).
3. Remove the front muffler heat protector(A)
4. Remove the front muffler(B).
5. Remove the exhaust manifold and catalytic converter assembly(A).
6. Using the SST(09215-3C000) and remove the oil pan.
CAUTION:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
- After tapping the SST with a plastic hammer along the direction of 2 arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It can be result in damage of the SST.
Oil Pump
1. Drain the engine oil.
2. Remove the drive belts.
3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
4. Remove the timing belt.
5. Remove the timing belt tensioner(A).
6. Remove the oil pan and oil screen.
7. Remove the alternator. .
8. Remove the air conditioner compressor tensioner bracket(A).
9. Remove the front case.
(1) Remove the screw from the pump housing, then separate the housing and cover(A).
(2) Remove the inner rotor(A) and outer rotor(B).
Disassembly
Relief Plunger
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
Inspection
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.6mm (1.8346in)
Load : 6.1±0.4kg/40.1mm (13.4±0.9 lb/1.5787in)
3. Inspect the rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
4. Inspect the rotor tip clearance.
Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips.
Tip clearance
0.025 - 0.069mm (0.0010 - 0.0027in)
If the tip clearance is greater than specified, replace the rotors as a set.
5. Inspect the rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.060 - 0.090mm (0.0024 - 0.0035in)
If the body clearance is greater than specified, replace the rotors as a set. If necessary, replace the front case.
Engine Oil
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F" marks in the dipstick.
If low, check for leakage and add oil up to the "F" mark.
NOTE:
Do not fill with engine oil above the "F" mark.
Selection Of Engine Oil
Recommendation : 5W-20/GF4&SM (If not available, refer to the recommended API or ILSAC classification and SAE viscosity number.)
API classification : SL, SM or above
ILSAC classification : GF3, GF4 or above
SAE viscosity grade : Refer to the recommended SAE viscosity number.
NOTE:
For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API or ILSAC classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API or ILSAC service classification on the container should not be used.
Reassembly
Relief Plunger
1. Install the relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque :
39.2 - 49.0N.m (4.0 - 5.0kgf.m, 28.9 - 36.2lb-ft)
Installation
Oil Pump
1. Install the oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover(A) to front case with the 7 screws.
Tightening torque :
5.9 - 6.9N.m (0.6 - 0.7kgf.m, 4.3 - 5.1lb-ft)
2. Check that the oil pump turns freely.
3. Install the oil pump on the cylinder block.
(1) Place a new front case gasket on the cylinder block.
(2) Apply engine oil to the lip of the oil pump seal. Then, install the oil pump onto the crankshaft.
(3) When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
Bolt length
(A) : 30mm (1.181in), (B) : 22mm (0.866in),
(C) : 45mm (1.772in), (D) : 60mm (2.362in)
Tightening torque :
18.6 - 23.5N.m (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
4. Apply a light coat of oil to the front case oil seal lip.
5. Using the SST(09214-32000),install the front case oil seal.
6. Install the air conditioner compressor tensioner bracket (A).
7. Install the alternator. .
8. Install the oil screen.
Tightening torque :
14.7 - 21.6N.m (1.5 - 2.2kgf.m, 10.8 - 15.9lb-ft)
9. Install the oil pan.
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
Clean the oil pan gasket mating surfaces.
10. Install the timing belt tensioner.
11. Install the timing belt.
12. Install the drive belts.
13. Fill with engine oil.
Oil Pan
1. Install the oil pan.
(1) Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
NOTE:
Check that the mating surfaces are clean and dry before applying liquid gasket.
(2) Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket :TB1217H or equivalent
NOTE:
- To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pan(A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
2. Install the exhaust manifold and catalytic converter assembly(A).
3. Install the front muffler(B).
Tightening torque :
29.4 - 39.2N.m (3.0 - 4.0kgf.m, 21.7 - 28.9lb-ft)
4. Install the front muffler heat protector(A).
5. Connect the rear oxygen sensor connector(A).
6. Fill with engine oil