Removal and Installation

OIL PUMP

Components:

Components 2wd:

Components 4wd:

Components:

Components 2wd:

Components 4wd:

Components:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait for least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. DRAIN ENGINE OIL (for 2WD)
4. DRAIN ENGINE OIL (for 4WD)
5. DRAIN ENGINE COOLANT
6. DRAIN AUTOMATIC TRANSMISSION FLUID (for 2WD)
7. DRAIN AUTOMATIC TRANSMISSION FLUID (for 4WD)
8. DRAIN FRONT DIFFERENTIAL OIL (for 4WD)
a. Drain the differential oil plug.

9. REMOVE ENGINE AND TRANSMISSION
a. Remove the engine and transmission assembly.

10. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
11. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
12. REMOVE ENGINE WIRE
a. Remove the engine wire.

13. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
14. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
15. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
16. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)
17. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)
18. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY
19. REMOVE FRONT ENGINE MOUNTING INSULATOR
20. REMOVE FRONT DIFFERENTIAL ASSEMBLY (for 4WD)
21. FIX ENGINE ONTO ENGINE STAND
22. REMOVE GENERATOR ASSEMBLY
23. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)
26. REMOVE WATER PUMP PULLEY
27. REMOVE INJECTOR DRIVER
28. REMOVE WATER INLET ASSEMBLY
29. REMOVE CRANKSHAFT PULLEY
30. REMOVE NO.2 OIL PAN SUB-ASSEMBLY (for 2WD)
31. REMOVE OIL PAN SUB-ASSEMBLY NO.2 (for 4WD)
32. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)
33. REMOVE OIL PAN SUB-ASSEMBLY (for 2WD)
34. REMOVE OIL PAN SUB-ASSEMBLY (for 4WD)
35. REMOVE OIL STRAINER SUB-ASSEMBLY (for 2WD)
36. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)
37. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
38. REMOVE NO.1 FUEL PIPE SUB-ASSEMBLY
39. REMOVE FUEL MAIN TUBE
40. REMOVE HIGH PRESSURE SIDE FUEL PUMP
41. REMOVE NO.2 FUEL PIPE SUB-ASSEMBLY
42. REMOVE IGNITION COIL ASSEMBLY
43. REMOVE NO.1 OIL PIPE
44. REMOVE NO.2 OIL PIPE
45. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
46. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

47. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the bolt and wiring harness clamp bracket.

b. Remove the 25 bolts and 2 nuts shown in the illustration.

c. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

HINT: Tape the screwdriver tip before use.

d. Remove the gasket.

INSTALLATION
1. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Apply seal packing in a continuous bead to the engine unit as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 inch)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially 7 areas indicated by C in the illustration.
^ When the contact surfaces are wet, wipe of with an oil-free cloth before applying seal packing.
^ Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

b. Apply seal packing in a continuous bead to the timing chain cover as shown in the illustration.

Seal packing: Part No.08826-00080 or equivalent
Seal packing: Part No.08826-00100 or equivalent

NOTICE:
^ When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
^ Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

HINT: Apply seal packing referring to the table and illustration below.

c. Install a new gasket.

d. Align the oil pump drive rotor splines and the crankshaft as shown in the illustration. Install the spline an chain cover to the crankshaft.

e. Install the timing chain cover with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt A 21 Nm (214 kgf-cm, 15 ft. lbs.) for except bolt A 21 Nm (214 kgf-cm, 15 ft. lbs.) for nut

NOTICE: Make sure that there is no oil on the bolt threads.

f. Install the bolt and wiring harness bracket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

2. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
4. INSTALL NO.2 OIL PIPE
5. INSTALL NO.1 OIL PIPE
6. INSTALL IGNITION COIL ASSEMBLY
7. INSTALL NO.2 FUEL PIPE SUB-ASSEMBLY
8. INSTALL HIGH PRESSURE SIDE FUEL PUMP
9. INSTALL FUEL MAIN TUBE
10. INSTALL NO.1 FUEL PIPE SUB-ASSEMBLY
11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
12. INSTALL OIL STRAINER SUB-ASSEMBLY (for 2WD)
13. REMOVE OIL PAN SUB-ASSEMBLY (for 4WD)
14. INSTALL OIL PAN SUB-ASSEMBLY (for 2WD)
15. REMOVE OIL PAN SUB-ASSEMBLY (for 4WD)
16. INSTALL OIL STRAINER SUB-ASSEMBLY (for 4WD)
17. INSTALL NO.2 OIL PAN SUB-ASSEMBLY (for 2WD)
18. REMOVE OIL PAN SUB-ASSY (for 4WD)
19. INSTALL CRANKSHAFT PULLEY
20. INSTALL WATER INLET ASSEMBLY
21. INSTALL INJECTOR DRIVER
22. INSTALL WATER PUMP PULLEY
23. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
24. INSTALL V-RIBBED BELT TENSIONER ASSY (for 4WD)
25. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY
26. INSTALL GENERATOR ASSEMBLY
27. REMOVE ENGINE STAND
28. INSTALL FRONT DIFFERENTIAL ASSEMBLY (for 4WD)
29. INSTALL FRONT ENGINE MOUNTING INSULATOR
30. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
31. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)
32. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)
33. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
34. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
35. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
36. INSTALL ENGINE WIRE
a. Install the engine wire to the engine assembly

37. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
38. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
39. INSTALL ENGINE AND TRANSMISSION
a. Install the engine and transmission to the body.

40. ADD ENGINE OIL (for 2WD)
41. INSTALL ENGINE OIL (for 4WD)
42. ADD AUTOMATIC TRANSMISSION FLUID (for 2WD)
43. ADD AUTOMATIC TRANSMISSION FLUID (for 4WD)
44. ADD FRONT DIFFERENTIAL OIL (for 4WD)
45. ADD ENGINE COOLANT
46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
47. PERFORM INITIALIZATION
a. Perform initialization procedure.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

48. CHECK SHIFT LEVER POSITION (for 2WD)
49. REMOVE SHIFT LEVER POSITION (for 4WD)
50. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
51. CHECK IGNITION TIMING
52. CHECK IDLE SPEED
53. CHECK CO/HC
54. CHECK FOR ENGINE OIL LEAKS
55. CHECK FOR ENGINE COOLANT LEAKS
56. CHECK FOR FUEL LEAKS
57. CHECK ENGINE OIL LEVEL
58. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
59. CHECK ENGINE COOLANT LEVEL