Removal and Installation

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE ENGINE UNDER COVER ASSEMBLY
a. W/engine under cover assembly
2. REMOVE ENGINE UNDER COVER NO. 1
3. REMOVE ENGINE UNDER COVER NO. 2
a. W/engine under cover No. 2
4. DRAIN ENGINE OIL
5. REMOVE FRONT WHEEL RH
6. REMOVE FR WIPER ARM RH
7. REMOVE FR WIPER ARM LH
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
9. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
10. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
11. REMOVE FRONT FENDER APRON SEAL RH
12. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
13. REMOVE GENERATOR ASSEMBLY
14. REMOVE VANE PUMP V BELT
15. REMOVE ENGINE MOVING CONTROL ROD
16. REMOVE ENGINE MOUNTING STAY NO. 2 RH
17. REMOVE GENERATOR BRACKET NO. 2
18. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
19. REMOVE TIMING BELT NO. 1 COVER
20. REMOVE TIMING BELT NO. 2 COVER
21. REMOVE ENGINE MOUNTING BRACKET RH
22. REMOVE TIMING BELT GUIDE NO. 2
23. REMOVE TIMING BELT
24. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 2
25. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
26. REMOVE TIMING BELT NO. 3 COVER
27. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 1
28. REMOVE CRANKSHAFT TIMING PULLEY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011)
29. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
30. REMOVE EXHAUST PIPE ASSEMBLY FRONT
31. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
32. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
33. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
34. REMOVE EXHAUST MANIFOLD CONVERTER SUB ASSEMBLY NO. 2
35. REMOVE OIL LEVEL GAGE GUIDE

36. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts and 2 nuts, then remove the adjusting bar.

37. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt and nut, then remove the adjusting bar bracket.
b. Remove the 3 bolts and the compressor.

HINT: Secure the hoses off to the side instead of detaching.

38. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
a. Remove the 2 bolts and the compressor mounting bracket No. 1.

39. SEPARATE ENGINE MOUNTING INSULATOR RR
a. Remove the 2 nuts and separate the engine mounting insulator RR.

40. SEPARATE ENGINE MOUNTING INSULATOR FR
a. Remove the 4 nuts and separate the engine mounting insulator FR.

NOTICE: Do not remove the engine mounting insulator FR.

41. REMOVE ENGINE MOUNTING INSULATOR RH
a. Remove the bolt and disconnect the power steering return hose clamp from the frame.
b. Remove the 4 nuts.
c. Place a wooden block on a jack underneath the engine.
d. Jack-up the engine and remove the engine mounting insulator RH.

NOTICE: Be careful not to damage the oil pan.

42. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and nut, then remove the bracket.
43. REMOVE OIL PAN SUB-ASSEMBLY NO. 2

a. Remove the 10 bolts and 2 nuts.

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

NOTICE:
^ Be careful not to damage the contact surface of oil pan No. 1 where oil pan No. 2 is mounted.
^ Do not damage the flange portion of oil pan No. 2 when removing.

44. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts, and remove the oil strainer and the gasket.
45. REMOVE OIL PAN SUB-ASSEMBLY

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

b. Loosen and remove the 17 bolts and 2 nuts uniformly.

c. Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.

NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.

46. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector.
b. Remove the bolt and the crankshaft position sensor.

47. REMOVE OIL PUMP ASSEMBLY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
c. Remove the O-ring.

INSTALLATION

1. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply MP grease to the oil seal lip.
2. INSTALL OIL PUMP ASSEMBLY
a. Remove any old seal packing material from the contact surface.

b. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.

c. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

d. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.

e. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (199 kgf-cm, 14 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)

3. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)

4. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in the region X.
^ Apply seal packing to the inner side of the bolt holes in the region Y.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install oil pan No. 1 with the 17 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
14 mm head 37 Nm (379 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 SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

6. INSTALL OIL PAN SUB-ASSEMBLY NO. 2
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

7. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the 4 bolts and nut and engine mounting bracket RH.
Torque:
Bolt A 54 Nm (551 kgf-cm, 40 ft. lbs.)
Nut B 54 Nm (551 kgf-cm, 40 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)

8. INSTALL ENGINE MOUNTING INSULATOR RH
a. Install the 4 nuts and nut and engine mounting insulator RH.
Torque:
Nut A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Nut B 87 Nm (887 kgf-cm, 64 ft. lbs.)

9. INSTALL ENGINE MOUNTING INSULATOR FR
a. Install the 4 nuts and engine mounting insulator FR.
Torque:
Nut A 87 Nm (887 kgf-cm, 64 ft. lbs.)
Nut B 52 Nm (530 kgf-cm, 38 ft. lbs.)

10. INSTALL ENGINE MOUNTING INSULATOR RR
a. Install the 2 nuts and engine insulator RR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
11. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
Bolt 25 Nm (250 kgf-cm, 18 ft. lbs.)
Nut 26 Nm (265 kgf-cm, 19 ft. lbs.)

13. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
Nut A 43 Nm (438 kgf-cm, 32 ft. lbs.)
Torque:
Bolt B 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt C 8.4 Nm (85 kgf-cm, 74 inch lbs.)
14. INSTALL OIL LEVEL GAGE GUIDE
15. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
16. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
17. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3
18. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1
19. INSTALL EXHAUST PIPE ASSEMBLY FRONT
20. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
21. INSTALL CRANKSHAFT TIMING PULLEY
22. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 1
23. INSTALL TIMING BELT NO. 3 COVER
24. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
25. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO. 2
26. INSPECT TIMING BELT
27. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
28. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
29. INSTALL TIMING BELT GUIDE NO. 2
30. INSTALL ENGINE MOUNTING BRACKET RH
31. INSTALL TIMING BELT NO. 2 COVER
32. INSTALL TIMING BELT NO. 1 COVER
33. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
34. INSTALL GENERATOR BRACKET NO. 2
35. INSTALL ENGINE MOUNTING STAY NO. 2 RH
36. INSTALL ENGINE MOVING CONTROL ROD
37. INSTALL VANE PUMP V BELT
38. INSTALL GENERATOR ASSEMBLY
39. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
40. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
41. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
42. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
43. INSTALL FR WIPER ARM LH
44. INSTALL FR WIPER ARM RH
45. INSTALL FRONT WHEEL RH
46. ADD ENGINE OIL
47. CHECK FOR ENGINE OIL LEAKS
48. CHECK FOR EXHAUST GAS LEAKS