Removal and Installation

REMOVAL

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

1. DRAIN ENGINE OIL
2. REMOVE RH FRONT WHEEL
3. REMOVE RH FENDER APRON SEAL
4. REMOVE FRONT EXHAUST PIPE
5. REMOVE GENERATOR FROM ENGINE
6. REMOVE A/C COMPRESSOR FROM ENGINE





7. 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.
8. REMOVE TIMING BELT. Refer to Timing Belt; Service and Repair; Removal.
9. REMOVE TIMING PULLEYS
10. REMOVE NO.3 TIMING BELT COVER





11. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 2 bolts and housing bracket.





12. REMOVE OIL LEVEL SENSOR
a. Disconnect the level sensor connector.
b. Remove the 2 bolts and nut, and disconnect the engine wire.
c. Remove the 4 bolts and oil level sensor.
d. Remove the gasket from the level sensor.

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

13. 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.





14. REMOVE OIL STRAINER
Remove the bolt, 2 nuts, oil strainer and gasket.
15. REMOVE NO.1 OIL PAN





a. Remove the 2 bolts and flywheel housing under cover.
b. Remove the 19 bolts.





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.

16. REMOVE BAFFLE PLATE FROM NO.1 OIL PAN
17. REMOVE CRANKSHAFT POSITION SENSOR





18. 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 (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 (80 kgf-cm, 69 inch lbs.)
12 mm head: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
2. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
3. INSTALL BAFFLE PLATE TO NO.1 OIL PAN
Torque: 8 Nm (80 kgf-cm, 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 3 - 4 mm (0.12 - 0.16 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 oil pan with the 19 bolts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head: 8 Nm (80 kgf-cm, 69 inch lbs.)
12 mm head: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
14 mm head: 37.2 Nm (380 kgf-cm, 27 ft. lbs.)
d. Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
5. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the bolt and 2 nuts,
Torque: 8 Nm (80 kgf-cm, 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. 08826-00080 or equivalent
Install a nozzle that has been cut to a 4 - 5 mm (0.0 - 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 (80 kgf-cm, 69 inch lbs.)





7. INSTALL OIL LEVEL SENSOR
a. Install a new gasket to the level sensor.
b. Install the level sensor with the 4 bolts.
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
c. Connect the engine wire with the 2 bolts and nut.
d. Connect the level sensor connector.
8. INSTALL A/C COMPRESSOR HOUSING BRACKET
Torque: 25 Nm (250 kgf-cm, 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 (440 kgf-cm, 32 ft. lbs.)
c. Tighten the nut.
Torque: 43.1 Nm (440 kgf-cm, 32 ft. lbs.)
13. INSTALL A/C COMPRESSOR
14. INSTALL GENERATOR
15. INSTALL RH FENDER APRON SEAL
16. INSTALL FRONT EXHAUST PIPE
17. INSTALL RH FRONT WHEEL
18. FILL ENGINE WITH OIL
19. START ENGINE AND CHECK FOR LEAKS
20. RECHECK ENGINE OIL LEVEL