Removal and Installation

Part 1 Of 2:

Part 2 Of 2:

REMOVAL

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

1. REMOVE ENGINE WITH TRANSMISSION
2. SEPARATE ENGINE AND TRANSMISSION
3. INSTALL ENGINE TO ENGINE STAND FOR REMOVAL
4. REMOVE CRANKSHAFT POSITION
5. REMOVE TIMING BELT, IDLER PULLEY AND CRANK SHAFT TIMING PULLEY





6. REMOVE OIL DIPSTICK AND GUIDE
a. Disconnect the engine wire clamp from the dipstick guide.
b. Remove the bolt.
c. Pull out the dipstick guide together with the dipstick.
d. Remove the O-ring from the dipstick guide.





7. REMOVE OIL LEVEL SENSOR
a. Disconnect the level sensor connector.
b. Remove the 4 bolts and level sensor.
c. Remove the gasket from the level sensor.

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

8. REMOVE NO.2 OIL PAN
a. Remove the 16 bolts and 2 nuts.





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

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





9. REMOVE OIL STRAINER
Remove the bolt, 2 nuts, oil strainer and gasket.
10. REMOVE OIL PAN BAFFLE PLATE
Remove the 6 bolts and baffle plate.





11. REMOVE NO.1 OIL PAN
a. Remove the 22 bolts.
b. Remove the No.1 oil pan by prying the portions between the cylinder block and No.1 oil pan with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan.

c. Remove the O-ring from the cylinder block.





12. REMOVE OIL PUMP
a. Remove the 9 bolts.
b. Using a hammer and a brass bar, remove the oil pump by carefully tapping the oil pump body.
c. Remove the 2 O-rings from the cylinder block.

INSTALLATION
1. INSTALL OIL PUMP





a. Place 2 new O-rings in position on the cylinder block.
b. 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 gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the debris.
^ Using a non-residue solvent, clean both sealing surfaces.

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





c. Apply seal packing to the oil pump as shown in the illustration.
Seal packing: Part No.0882-00080 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. Be particularly careful near oil passages.

^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle tram the tube and reinstall cap.





d. Install the oil pump with the 9 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
2. INSTALL NO.1 OIL PAN





a. Place a new O-ring in the position on the cylinder block.
b. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 oil pan and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the debris.
^ Using a non-residue solvent, clean both sealing surfaces.

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





c. Apply seal packing to the No.1 oil pan as shown in the illustration.
Seal packing: Part No.0882-00080 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 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.

d. Install the No.1 oil pan with the 22 bolts.
Torque:
12 mm head 21 Nm (210 kgf-cm, 15 ft. lbs.)
14 mm head 40 Nm (400 kgf-cm, 30 ft. lbs.)
3. INSTALL OIL PAN BAFFLE PLATE
Torque: 9.0 Nm (90 kgf-cm, 80 inch lbs.)
4. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 9.0 Nm (90 kgf-cm, 80 inch lbs.)





5. INSTALL NO.2 OIL PAN
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces 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 groove.
^ Thoroughly clean all components to remove all the debris.
^ 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.08826-0080 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 5 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 16 bolts and 2 nuts.
Torque: 9.0 Nm (90 kgf-cm, 80 ft. lbs.)





6. INSTALL OIL LEVEL SENSOR
a. Install a new gasket to the level sensor.
b. Install the level sensor with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
c. Connect the level sensor connector.





7. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
a. Install a new O-ring on the dipstick guide.
b. Apply soapy water on the O-ring.
c. Push in the dipstick guide into the guide hole of the No.1 oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
f. Connect the engine wire clamp to the dipstick guide.
8. INSTALL CRANKSHAFT TIMING PULLEY, IDLER PULLEY AND TIMING BELT
9. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 Nm (90 kgf-cm, 80 inch lbs.)
10. REMOVE ENGINE STAND FROM ENGINE
11. ASSEMBLY ENGINE AND TRANSMISSION
12. INSTALL ENGINE WITH TRANSMISSION