Oil Pump Replace

COMPONENTS FOR OIL PUMP REMOVAL AND INSTALLATION

OIL PUMP REMOVAL

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

1. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY

CAUTION: Work must be started after 90 seconds from the time the ignition switch 1s turned to the -LOCK- position and the negative (-) terminal cable is disconnected from the battery.

2. DRAIN ENGINE OIL
3. REMOVE OIL DIPSTICK
4. REMOVE TIMING BELT
5. REMOVE TIMING PULLEYS
6. DISCONNECT ENGINE WIRE

(a) Disconnect the crankshaft position sensor connector.
(b) Disconnect the engine wire from the wire clamp.

(c) Disconnect the generator connector.
(d) Remove the nut and disconnect the generator wire.
(e) Disconnect the engine wire from the 3 clamps.

7. REMOVE NO.3 TIMING BELT COVER
Remove the 6 bolts and belt cover.

8. REMOVE GENERATOR
Remove the 2 bolts and generator.

9. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and position sensor.

10. REMOVE OIL HOLE COVER PLATE
Remove the 4 bolts and cover plate.

11. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the 5 bolts, 2 nuts and drive belt adjusting bar bracket, and disconnect the A/C compressor.
(d) Move the compressor aside and suspend it.

12. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 3 bolts and A/C compressor housing bracket.

13. REMOVE FRONT EXHAUST PIPE

(a) Remove the 2 bolts and exhaust pipe clamp.

(b) Remove the 2 bolts, and disconnect the bracket.
(c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the three-way catalytic converter.
(d) Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
(e) Remove the front exhaust pipe and 3 gaskets.

14. REMOVE FRONT EXHAUST PIPE STAY
Remove the 2 bolts and pipe stay.

15. REMOVE FLYWHEEL HOUSING UNDERCOVER
Remove the 2 bolts and undercover.

16. REMOVE BOLTS HOLDING NO.1 OIL PAN TO TRANSAXLE
Remove the 2 bolts.
17. 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 aurface of the No.1 oil pan.
^ Be careful not to damage the No.2 oil pan flange.

18. REMOVE OIL STRAINER
Remove the bolt, 2 nuts, oil strainer and gasket.

19. REMOVE NO.1 OIL PAN

(a) Remove the 17 bolts.

(b) Using a screwdriver, remove the No.1 oil pan by prying the portions between the cylinder block and No.1 oil pan.

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

20. REMOVE OIL PAN BAFFLE PLATE
Remove the 6 bolts and baffle plate.

21. 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 0-ring.

OIL PUMP 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 in.) 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.

(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.

Torque:
8 N.m (80 kgf.cm, 69 in..lbf) for 10 mm head bolt
19.5 N.m (200 kgf.cm, 14 ft.lbf) for 12 mm head bolt

2. INSTALL OIL PAN BAFFLE PLATE
- Install the baffle plate with the 6 bolts.

Torque: 8 N.m (80 kgf.cm, 69 in.lbf)

3. 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 in.) 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 17 bolts.

Torque:
8 N.m (80 kgf.cm, 69 in.lbf) for 10 mm head bolt
19.5 N.m (200 kgf.cm. 14 ft.lbf) for 12 mm head bolt

4. INSTALL OIL STRAINER
- Install a new gasket and the oil strainer with the bolt and 2 nuts.

Torque: 8 N.m (80 kgf.cm, 69 in.lbf)

5. 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 (0.16- 0.20 in.) 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.

6. INSTALL BOLTS HOLDING NO.1 OIL PAN TO TRANSAXLE
- Install the 2 bolts.

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)

7. INSTALL FLYWHEEL HOUSING UNDERCOVER
- Install the undercover with the 2 bolts.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)

6. INSTALL FRONT EXHAUST PIPE STAY
- Install the pipe stay with the 2 bolts.

Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

9. INSTALL FRONT EXHAUST PIPE
(a) Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts.
(b) Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.

Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)

(c) Tighten the 2 bolts and 2 nuts holding the three-way catalytic converter to the front exhaust pipe.

Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)

(d) Connect the bracket with the 2 bolts.

Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)

(e) Connect the front exhaust pipe clamp with the 2 bolts.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

10. INSTALL A/C COMPRESSOR HOUSING BRACKET
- Install the housing bracket with the 3 bolts.

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

11. INSTALL A/C COMPRESSOR
(a) Install the A/C compressor and drive belt adjusting bar bracket with the 5 bolts.

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

12. INSTALL OIL HOLE COVER PLATE
- Install a new gasket and the hole cover plate (J mark facing outward) with the 4 bolts.

Torque: 8 N.m (SO kgf.cm. 69 in.lbf)

13. INSTALL CRANKSHAFT POSITION SENSOR
- Install the position sensor with the bolt.

Torque: 8 N.m (80 kgf.cm. 69 in.lbf)

14. INSTALL GENERATOR
- Install the generator with the 2 bolts. Do not tighten the bolts yet.

15. INSTALL NO.3 TIMING BELT COVER

(a) Check that the timing belt cover gaskets have no cracks or peeling, etc.

If the gaskets do have cracks or peeling etc., replace them using the following steps.
(1) Using a screwdriver and gasket scraper. remove all the old gasket material.
(2) Thoroughly clean all components to remove all the loose material.
(3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration.

NOTICE: When joining gaskets, do not leave a gap between them. Cut off any excess gasket.

(4) After installing the gasket. press down on it so that the adhesive firmly sticks to the belt cover.

(b) Install new gaskets to the No.3 belt cover.

16. CONNECT ENGINE WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the engine wire with the 3 clamps.

(d) Connect the crankshaft position sensor connector.
(e) Connect the engine wire with the wire clamp.

17. INSTALL TIMING PULLEYS
18. INSTALL TIMING BELT
19. FILL ENGINE WITH OIL

Drain And Refill Capacity:
w/ Oil filter change: 4.7 liter (5.0 US qts, 4.1 Imp. qts)
w/o Oil filter change: 4.5 liter (4.8 US qts, 4.0 Imp. qts)

20. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
21. START ENGINE AND CHECK FOR LEAKS
22. RECHECK ENGINE ENGINE OIL LEVEL