Oil Pump ASSY: Replacement

1. Remove the bolt holding the guide to the LH cylinder head.
2. Pull out the guide together with the level gage from the oil pan.
3. Remove the O-ring from the guide.
   Fig 1: Removing Oil Level Gage Guide

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1. Remove the 4 bolts and sensor.
2. Remove the gasket from the sensor.

1. Disconnect the 2 water by-pass hoses from the oil cooler.
2. Disconnect the oil pressure switch connector.
3. Remove the stud bolt, 2 nuts and the filter bracket together with the oil filter and oil cooler assembly.
4. Remove the gasket from the filter bracket.

1. Disconnect the sensor connector.
2. Remove the bolt and sensor.

1. Remove the 13 bolts and 2 nuts.
2. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, cut through the sealer and remove the oil pan No. 2.

1. SST 09032-00100

Fig 2: Removing Oil Pan Sub-Assy No. 2

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Remove the 4 bolts, 2 nuts and baffle plate.

Fig 3: Removing Oil Pan Baffle Plate

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1. Remove the 18 bolts and 2 nuts.
   Fig 4: Removing Oil Pan Sub-Assy Bolts And Nuts

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

Fig 5: Removing Oil Pan Prying Portions Between Cylinder Block And Oil Pan

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1. Remove the bolt, 2 nuts, oil strainer and gasket.

1. Remove the 8 bolts.

   HINT:

   Use a 6 mm hexagon wrench for the hexagon head bolt.

   Fig 6: Removing Oil Pump Assy Bolts

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2. Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.
   Fig 7: Removing Oil Pump Prying Portions Between Oil Pump And Cylinder Block

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

1. Using a screwdriver, pry out the seal.

HINT:

Tape the screwdriver tip before use.

Fig 8: Removing Oil Pump Seal

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1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
   1. SST 09316-6001 1 (09316-00011)
   NOTE: Be careful not to tap the oil seal in at an angle.
2. Apply a small amount of MP grease to the oil seal lip.
   Fig 9: Installing Oil Pump Seal

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1. Apply seal packing to the oil pump as shown in Fig 10 .
   1. Seal packing: Part No. 08226-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pump within 3 minutes after applying seal packing.
   • Do not put into engine oil for at least 2 hours after installing.
   Fig 10: Applying Seal Packing To Oil Pump

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2. Apply engine oil to new O-ring.
3. Install a the O-ring on the cylinder block.
   Fig 11: Installing O-Ring On Cylinder Block

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4. 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.
5. Install the oil pump with the 8 bolts. Uniformly tighten the bolts in several passes.
Fig 12: Installing Oil Pump Bolts
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1. Torque: 
2. 15.5 N.m (160 kgf.cm, 11 ft.lbf) for 12 mm head (A, C), stud bolt (B) and 6 mm hexagon head (E) 
3. 30.5 N.m (310 kgf.cm, 22 ft.lbf) for 14 mm head (D) 

HINT:

• Use a 6 mm hexagon wrench for the hexagon head bolt.
• Each bolt length is indicated below.

1. Bolt length:
   • A (12 mm head): 50 mm (1.97 in.)
   • B (12 mm head): 106 mm (4.17 in.)
   • C (12 mm head): 30 mm (1.18 in.)
   • D (14 mm head): 44 mm (1.73 in.)
   • E (6 mm hexagon head): 28 mm (1.10 in.)

1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

HINT:

Use a bolt that is 12 mm (0.47 in.) in length.

Fig 13: Installing Oil Strainer Sub-Assy

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1. Apply seal packing to the oil pan as shown in Fig 14 .
   1. Seal packing: Part No. 08226-00080 or equivalent 
   NOTE:

   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not put into engine oil for at least 2 hours after installing.
   • Remove any oil from the contact surface.
   Fig 14: Applying Seal Packing To Oil Pan

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2. Temporarily install the oil pan with the 18 bolts and 2 nuts.

   HINT:

   Each bolt length is indicated below.

   1. Bolt length:
      • A (10 mm head): 20 mm (0.79 in.)
      • B (10 mm head): 35 mm (1.38 in.)
      • C (12 mm head): 60 mm (2.36 in.)
      • D (12 mm head): 25 mm (0.98 in.)
      Fig 15: Installing Oil Pan Bolts And Nuts

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3. Set the No. 1 oil pan as shown in Fig 15 .
   NOTE: Make sure the clearance between the rear ends of the No. 1 oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the clearance is more than 0.2 mm (0.008 in.), the No. 1 oil pan will deform when tightening the bolts, stud bolts and nuts.
4. Uniformly tighten the bolts, stud bolts and nuts in several passes.

1. Torque: 
2. 7.5 N.m (76 kgf.cm, 66 in.lbf) for 10 mm head 
3. 28 N.m (286 kgf.cm, 21 ft.lbf) for 12 mm head 

1. Install the baffle plate with the 4 bolts and 2 nuts.

1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Fig 16: Installing Oil Pan Baffle Plate

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1. Apply seal packing to the oil pan as shown in Fig 17 .
   1. Seal packing: Part No. 08226-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the oil pan within 3 minutes after applying seal packing.
   • Do not put into engine oil for at least 2 hours after installing.
2. Install the oil pan with the 13 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

Fig 17: Installing Oil Pan Sub-Assy No. 2

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1. Install a new gasket to the sensor as shown in Fig 18 .
2. Install the sensor with the 4 bolts.

1. Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf) 

HINT:

Use a bolt that is 16 mm (0.63 in.) in length.

Fig 18: Installing Engine Oil Level Sensor

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1. Install the sensor with the bolt.
   1. Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf) 

   HINT:

   Use a bolt that is 17 mm (0.67 in.) in length.

2. Connect the sensor connector.

1. Install a new gasket to the filter bracket.
2. Install the filter bracket, oil filter and oil cooler assembly with the stud bolt and 2 nuts.
   1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
3. Connect the oil pressure switch connector.
4. Connect the 2 water by-pass hoses to the oil cooler.

1. Install a new O-ring to the gage guide.
2. Apply soapy water to the O-ring.
3. Push in the gage guide end into the guide hole of the No. 1 oil pan.
4. Install the gage guide with the bolt.
   1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 
5. Install the gage.
   Fig 19: Installing Oil Level Gage Guide

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