Engine Lubrication: Service and Repair

REMOVAL
1. Remove the timing belt.
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen.





5. Remove the front case assembly.
6. Remove the oil pump cover.
7. Remove the inner and outer gears from the front case. The mating marks on the inner and outer gears indicate the direction of installation. Make sure that the inner and outer gears are installed as shown.
8. Remove the plug and remove the relief spring and relief plunger.

INSTALLATION
Oil Pump
1. Install the outer and inner gears into the front case. Make sure that the inner and outer gears are installed in the same direction.





2. Install the oil pump cover and tighten the bolts to the specified torque. After the bolts have been tightened, check to ensure that the gear turns smoothly.
Tightening torque:
Oil pump cover bolt: 6-9 Nm (60-90 kg.cm, 4-6.6 ft. lbs.)
3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.
Tightening torque:
Relief valve plug: 40-50 Nm (400-500kg.cm, 29-36 ft. lbs.)

Front Case





Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.

Body length:
(A)25 mm (0.98 inch)
(B)20 mm (0.787 inch)
(C)38 mm (1.496 inch)
(D)45 mm (1.771 inch)

Tightening torque: 20-27 Nm (200-270 kg.cm, 14.5-19.8 ft. lbs.)

Oil Seal
1. Inspect for worn, distorted spring lips.
2. Check for elongated spring ring.
3. Always use a new oil seal when reassembling.








4. Use Special Tool, Mounting Bushing Remover and installer Arbor (09216-21000) or equivalent, install the oil seal.
5. Install the crankshaft sprocket, timing belt and crankshaft pulley.
6. Install the oil screen.
7. Clean both gasket surfaces of the oil pan and the cylinder block.





8. Apply sealant into the groove of the oil pan flange as shown.

CAUTION:
1) Apply sealant approx. 4 mm (0.16 inch) in thickness.
2) After application of sealant, do not exceed 15 minutes before installing the oil pan.

9. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque:
Oil pan bolt: 6-8 Nm (60-80 kg.cm, 4-6 ft. lbs.)