OIL PUMP REMOVAL


  1. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug and engine drain plug, then drain the coolant.

      A01BHB7E02

    2. Remove the radiator cap.

  2. DRAIN ENGINE OIL

    Note


    • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.

    • Exercise caution in order to minimize the duration and frequency of skin contact with used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents.

    • In order to preserve the environment, used oil and the used oil filter must be disposed of only at designated disposal sites.


    1. Remove the oil filler cap.

    2. Remove the oil drain plug, and drain the oil into a container.

    3. Clean the drain plug, and install it with a new gasket.

      Torque:
      35 N*m  { 350 kgf*cm, 25 ft.*lbf }

  3. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Turn back the carpet, and remove the engine service hole cover sub-assembly.

  6. REMOVE RADIATOR HOSE INLET

  7. REMOVE RADIATOR HOSE NO.4

  8. DISCONNECT WATER HOSE (for Heater)

  9. REMOVE VANE PUMP V BELT


    1. A01BCBTE01

      Loosen the bolt A and nut B, and remove the V belt.

  10. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (w/ Air Conditioning System)


    1. A01BEBYE01

      Loosen the nut A and bolt B, and remove the V belt.

  11. REMOVE FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A01BBR9E01

      Loosen the bolts A and B, and remove the V belt.

  12. REMOVE FAN & GENERATOR V BELT (w/ Air Conditioning System)


    1. A01BAGHE01

      Loosen the bolts A and B.

    2. Loosen the adjusting bolt C, and remove the V belt.

  13. REMOVE WATER PUMP PULLEY


    1. Remove the 4 nuts, fan spacer and fan pulley.

  14. REMOVE VENTURI ASSEMBLY


    1. A01BAY2E01

      Disconnect the throttle open switch connector.

    2. A01BFXZE01

      Disconnect the throttle control motor connector.

    3. Remove the venturi and gasket.

  15. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the connector.

    2. A01BGZO

      Remove the 4 bolts and compressor and magnetic clutch.

  16. REMOVE COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BDQD

      Remove the 3 bolts and compressor mounting bracket.

    2. A01BDNC

      Remove the bolt and spacer.

    3. A01BFW5

      Remove the 4 bolts and compressor mounting bracket.

  17. REMOVE VANE PUMP DRIVE PULLEY


    1. A01BCI8E01

      Using SST, remove the nut and the vane pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

  18. REMOVE CRANKSHAFT PULLEY


    1. A01BD00E01

      Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01BDH6E01

      Using SST, remove the pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      09950-60010   ( 09951-00490 )
      09950-40011   ( 09957-04010 )

  19. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. A01BFU5

      Remove the 11 bolts, washers, timing belt cover and 2 gaskets.

  20. REMOVE TIMING BELT GUIDE


    1. Remove the timing belt guide.

  21. REMOVE SET NO.1 CYLINDER TO TDC/COMPRESSION


    1. A01BEZ9E01

      Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.

    2. A01BCEAE01

      Check that the timing marks of the camshaft timing pulley and No.2 timing belt cover are aligned.

      If not, turn the crankshaft 1 revolution (360°).

  22. REMOVE TIMING BELT


    1. A01BHZKE01

      Remove the timing belt.

      Tech Tips

      If reusing the timing belt, draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the pulleys and timing belt.

    2. A01BBKOE01

      Turn the crankshaft 90° counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing gear case.

      Note

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley, causing damage. So always set the crankshaft pulley at the correct angle.

    3. A01BF04E01

      Loosen the timing belt idler No.1 bolt (A), and shift the idler to the left as far as possible.

    4. Temporarily tighten the pulley bolt (A), and then relieve the timing belt tension.

    5. Remove the timing belt.

  23. REMOVE INJECTION PUMP DRIVE PULLEY


    1. A01BEIWE01

      Using SST, remove the pulley nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
    2. A01BADXE01

      Using SST, remove the drive pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  24. REMOVE INJECTION PUMP


    1. Disconnect the engine speed sensor connector.

    2. Disconnect the spill control valve connector.

    3. Disconnect the correction unit connector.

    4. Disconnect the timer control valve connector.

    5. Disconnect the fuel temperature sensor connector.

    6. Disconnect the engine wire clamp.

    7. Disconnect the 3 fuel hoses.

    8. A01BBBJ

      Disconnect the 3 bolts and injection pump stay No.1.

    9. Remove the 2 nuts and injection or supply pump assembly.

  25. REMOVE TIMING BELT COVER NO.2


    1. Remove the 4 bolts and timing belt cover.

  26. REMOVE WATER PUMP ASSEMBLY


    1. A01BB70

      Remove the 6 bolts and tension spring bracket.

    2. Remove the water pump and gasket.

  27. REMOVE CAMSHAFT TIMING PULLEY


    1. A01BCYOE02

      Set the No.1 cylinder to approx. 90° BTDC/compression.

      Tech Tips

      Set the No.1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.


      1. Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing gear case.

    2. A01BG7SE02

      Using SST, loosen the pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    3. A01BDX8E02

      Using SST, separate the timing pulley from the camshaft.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

    4. Remove the pulley bolt and timing pulley.

    5. Remove the timing gear woodruff key.

  28. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A01BFLME01

      Remove the 2 bolts (A and B).

    2. Loosen the bolt (C), and remove the timing belt idler No.1.

  29. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2


    1. Remove the bolt, timing belt idler No.2 and spacer.

  30. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the 16 bolts and 2 nuts.

    2. A01BD5SE02

      Insert the blade of SST between the oil pan and cylinder block, and cut off applied sealer and remove the oil pan.

      SST
      09032-00100

      Note


      • Do not use SST for the timing belt case side and rear oil seal retainer.

      • Be careful not to damage the oil pan flange.

  31. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  32. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. A01BC44

      Remove the 5 bolts, timing gear case, and gasket.