Removal and Installation

REMOVAL


HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned.

1. Remove RH front wheel.
2. Remove RH fender apron seal.
3. Drain engine oil.
4. Remove front exhaust pipe.
5. Remove front exhaust pipe bracket from No.1 oil pan.
6. Remove generator drive belt.
7. Disconnect A/C compressor from engine.





8. Remove PS pump drive belt and adjusting strut.
a. Loosen the pivot and adjusting bolts, and remove the drive belt.
b. Remove the bolt, nut and adjusting strut.
9. Remove timing belt.
10. Remove timing pulleys.
11. Remove No.3 timing belt cover.





12. Remove A/C compressor housing bracket.
Remove the 3 bolts and housing bracket
13. Remove oil level sensor.

NOTICE: Be careful not to drop the oil level sensor when removing it.





14. Remove No.2 oil pan.
a. Remove the 10 bolts and 2 nuts.





b. Insert the blade of SST between the No.1 and No.2 oil pans, and cut off applied sealer and remove the No.1 oil pan.
SST 09032-00100

NOTICE:
- Be careful not to the damage the No.2 oil pan contact surface of the No.1 oil pan.
- Be careful not to damage the No.2 oil pan flange.





15. Remove oil strainer.
Remove the bolt, 2 nuts, oil strainer and gasket.





16. Remove No.1 oil pan.
a. Remove the 2 bolts, exhaust pipe support stay and flywheel housing under cover.
b. Remove the 17 bolts and 2 nuts.





c. 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.

17. Remove baffle plate from No.1 oil pan.
18. Remove crankshaft position sensor.





19. Remove oil pump.
a. Remove the 9 bolts.
b. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap.
c. Remove the O-ring.

INSTALLATION





1. Install oil pump.
a. Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the oil pump as shown in the illustration.

Seal packing: Part No. 08826-00080 or equivalent

- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap.





c. Place a new O-ring on the cylinder block.





d. 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.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.

Torque:
10 mm head: 8 Nm (69 inch lbs.)
12 mm head: 19.5 Nm (14 ft. lbs.)

2. Install crankshaft position sensor.

Torque: 8 Nm (69 inch lbs.)

3. Install baffle plate to No.1 oil pan.

Torque: 8 Nm (69 inch lbs.)





4. Install No.1 oil pan.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the oil pan as shown in the illustration.

Seal packing: Part No. 08826 00080 or equivalent

Region "X" is at the outer side of the bolt hole. Region "Y" is at the inner side of the bolt hole.

- Install a nozzle that has been cut to a 4- 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and rein stall cap.
c. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:
10 mm head: 8 Nm (69 inch lbs.)
12 mm head: 19.5 Nm (14 ft lbs.)
14 mm head: 37.2 Nm (27 ft. lbs.)

d. Install the flywheel housing under cover and exhaust pipe support stay with the 2 bolts.

Torque: 7.8 Nm (69 inch lbs.)

5. Install oil strainer.
Install a new gasket and the oil strainer with the bolt and 2 nuts.

Torque: 8 Nm (69 inch lbs.)





6. Install No.2 oil pan.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 and No.2 oil pans.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces.

NOTICE: Do not use a solvent which will affect the painted surfaces.

b. Apply seal packing to the No.2 oil pan as shown in the illustration.

Seal packing: Part No. 08820-00080 or equivalent

- Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.
c. Install the No.2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque: 8 Nm (69 inch lbs.)

7. Install oil level sensor.
Install a new gasket and the oil level sensor with the 4 bolts.

Torque: 8 Nm (69 inch lbs.)

8. Install A/C compressor housing bracket.

Torque: 25 Nm (18 ft. lbs.)

9. Install No.3 timing belt cover.
10. Install timing pulleys.
11. Install timing belt.
12. Install adjusting strut and PS pump drive belt.
a. Temporarily install the adjusting strut with the bolt and nut.
b. Install the drive belt with the pivot and adjusting bolts.

Torque: 43.1 Nm (32 ft. lbs.)

c. Tighten the nut.

Torque: 43.1 Nm (32 ft. lbs.)

13. Install A/C compressor.
14. Install generator drive belt.
15. install front exhaust pipe bracket to No.1 oil pan.

Torque: 21 Nm (15 ft. lbs.)

16. Install front exhaust pipe.
17. Install RH fender apron seal.
18. Install RH front wheel.
19. Fill engine with oil.
20. Start engine and check for leaks.
21. Recheck engine oil level.