OIL PUMP INSTALLATION


  1. INSTALL CRANK OIL SEAL


    1. A013733E01

      Using SST, tap in a new crank oil seal until its surface is flush with the oil pump case edge.

      SST
      09505-20010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  2. INSTALL OIL PUMP ASSEMBLY


    1. A0137G5E01

      Install a new O-ring to the oil pump assembly.

    2. A01363ZE01

      Apply a seal packing to the cylinder block as shown in the illustration.

      Seal packing
      Part No. 0826-00080 or equivalent

      Note


      • When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.

      • Install the oil pump assembly within 3 minutes after applying packing.

    3. A0137I0E02

      Align the flat sections of the oil pump drive gear with the flat sections located on the crankshaft, and slide the oil pump into place.

    4. A0136LTE01

      Tighten the 8 bolts in the order shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    5. Retighten the 8 bolts in the order shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  3. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A0136C0

      Install a new gasket to the oil strainer sub-assembly.

    2. Using a hexagon socket wrench, install the oil strainer sub-assembly with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  4. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01381U

      Apply seal packing to the cylinder block as shown in the illustration.

      Seal packing
      Part No. 08826-00080 or equivalent

      Note

      Install the oil pan sub-assembly within 5 minutes after applying packing.

    2. A0135XE

      Install the oil pan sub-assembly with the 15 bolts and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL CRANKSHAFT PULLEY


    1. Install the crankshaft timing pulley and key.

    2. A01386OE01

      Install crankshaft pulley with the bolt.

    3. Using SST, hold the crankshaft.

      SST
      09330-00021

    4. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 22 ft.*lbf }
    5. A0136QPE01

      Mark the top surface of the crankshaft pulley bolt with paint.

    6. Retighten the bolt by an additional 190 degrees as shown in the illustration.

  6. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A0137WYE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Apply adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Part No. 08833-00070, THREE BOND 1324 or equivalent
    3. A01367IE01

      Install the flywheel sub-assembly with the 6 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

    4. A01366QE01

      Mark the top surfaces of the flywheel bolts with paint.

    5. Retighten the bolts by an additional 70 degrees as shown in the illustration.

  7. REMOVE CRANKSHAFT PULLEY


    1. A0137WYE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Remove the bolt and crankshaft pulley.

  8. INSTALL CLUTCH DISC ASSEMBLY

    A0136R3E01

    1. Insert SST into the clutch disc, and then insert them into the flywheel.

      SST
      09301-00131

      Note

      Do not insert the clutch disc in the wrong direction.

  9. INSTALL CLUTCH COVER ASSEMBLY

    A0137J5E01

    1. Align the matchmark on the clutch cover with the one on the flywheel.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      After checking that the disc is in the center, gently move SST up and down, right and left to tighten the bolts.

      SST
      09301-00131

  10. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.

    2. A01373ME01

      Install the 7 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Install 3 A bolts from the transaxle side.

      • Install 4 B bolts from the engine side.

  11. INSTALL STARTER ASSEMBLY


    1. A0138HDE02

      Using a hexagon wrench (6 mm), install the starter with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the wire harness to terminal 30 and install the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the wire harness to terminal 50 and install the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Install the wire harness clamp bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  12. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01389H

      Install the engine with transaxle assembly to the crossmember sub-assembly and the engine mounting member with the bolt.

      Torque:
      120 N*m  { 1,224 kgf*cm, 89 ft.*lbf }

    2. Set the engine lifter.

    3. A0136HV

      Remove the chain block from the engine assembly with transaxle.

  13. REMOVE ENGINE MOUNT BRACKET


    1. A0138R6

      Remove the 4 bolts and engine mount bracket.

  14. SET TIMING MARK


    1. A0136QE

      Using SST, set the pulley of the camshaft so that the timing holes of the camshaft drive pulley and the cylinder head are aligned.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A0137Z1

      Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.

  15. INSTALL TIMING BELT


    1. A0138L6

      Temporarily install the timing belt tensioner with the bolt.

    2. Install the timing belt.

    3. A013842

      Check that the timing holes are aligned as shown in the illustration.

    4. A0137ALE01

      Using a hexagon socket wrench, turn the timing belt tensioner as shown in the illustration.

      Tech Tips

      Part A should be positioned within area B.

    5. Tighten the timing belt tensioner bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  16. CHECK VALVE TIMING


    1. A013842

      Slowly turn the crankshaft 2 complete revolutions (720°).

    2. Check that the timing holes are aligned as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  17. INSTALL CRANK POSITION SENSOR


    1. A0136ZP

      Install the crankshaft timing pulley support with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Install the crankshaft position sensor with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the crankshaft position sensor connector.

  18. INSTALL ENGINE MOUNT BRACKET


    1. A01374V

      Install the engine mount bracket with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  19. INSTALL TIMING BELT LOWER COVER


    1. A0135SJ

      Install the timing belt lower cover with the 5 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  20. INSTALL CRANKSHAFT PULLEY


    1. A0136NUE01

      Temporarily install the timing belt tensioner with the bolt.

    2. Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    3. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    4. A0136QPE01

      Mark the top surface of the crankshaft pulley bolt with paint.

    5. Retighten the bolt by an additional 190 degrees as shown in the illustration.

  21. INSTALL ALTERNATOR BRACKET NO.2 (w/ Air Conditioning System)


    1. A0137KY

      Install the alternator bracket No.2 with the 2 bolts and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  22. INSTALL GENERATOR ASSEMBLY (w/ Air Conditioning System)


    1. A0137E9E02

      Install the generator assembly with the 4 bolts.

      Torque:
      Bolt A
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
      Bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  23. INSTALL GENERATOR ASSEMBLY (w/o Air Conditioning System)


    1. Install the generator bracket No.2 with the 2 bolts to the generator assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Using a hexagon socket wrench, install the V-ribbed belt idler assembly No.1 with the bolt to the generator bracket No.2.

      Torque:
      48 N*m  { 490 kgf*cm, 35 ft.*lbf }
    3. A013920E01

      Install the generator assembly with generator bracket No.2 with the 4 bolts.

      Torque:
      Bolt A
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
      Bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      Bolt C
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Install the generator wire to terminal B with the nut.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    5. Install the terminal cap.

    6. Connect the generator connector.

  24. INSTALL V-RIBBED BELT TENSIONER SUB-ASSEMBLY


    1. A0137H7

      Install the V-ribbed belt tensioner sub-assembly with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  25. CONNECT WIRE HARNESS


    1. A0138SIE01

      w/ Air Conditioning System:


      1. Connect the wire harness to the generator assembly.

      2. Connect the compressor connector.

    2. A0137P9E01

      Connect the engine oil pressure switch connector.

  26. INSTALL STUD BOLT


    1. A0138ZOE01

      Using a "trox" socket wrench (E7), install the stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL OIL LEVEL GAUGE GUIDE


    1. A013776

      Install 2 new O-rings to the oil level gauge guide.

    2. A0137BX

      Install the oil level gauge guide with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  28. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY


    1. Install the oil level gauge.

  29. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A0136EB

      Temporarily install the exhaust manifold converter clamp, converter separator insulator No.1, catalytic converter support bracket, exhaust manifold converter sub-assembly and 2 nuts.

    2. Tighten the 2 nuts to the cylinder block.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Retighten the 2 nuts to the cylinder block.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Tighten the nut of the exhaust manifold converter clamp.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  30. INSTALL MANIFOLD HEAT SHIELD


    1. A0138LO

      Install the manifold heat shield with the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  31. INSTALL TURBO INSULATOR NO.1


    1. A0137BH

      Install the turbo insulator No.1 with the 7 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0136DLE01

      Install 4 new O-rings and a gasket to the cylinder head cover.

    2. Temporarily install the cylinder head cover with the 10 bolts.

    3. Tighten the 10 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A013789

      Connect the diesel throttle valve connector.

  33. INSTALL EGR VALVE ASSEMBLY


    1. Install a new O-ring to the EGR pipe.

    2. Temporarily install the EGR valve assembly and gasket with the 2 screws and 2 bolts.

    3. A0136D4

      Install the clamp with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    4. A01369N

      Tighten the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    5. A0137SF

      Using a "torx" socket wrench, tighten the 2 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  34. INSTALL EGR COOLER WATER BY-PASS HOSE


    1. A0137WQ

      Using pliers, slide the 2 clips to install the water by-pass hose.

  35. INSTALL HEATER WATER OUTLET HOSE A


    1. A0137MH

      Using pliers, slide the clip to install the heater water outlet hose A.

  36. INSTALL ENGINE WIRE NO.2


    1. A0136C6

      Install the engine wire No.2 to the injector.

      CAUTION:

      Be sure to connect the injector connectors correctly to prevent malfunctions in the injector.

    2. A0135V2

      Connect the fuel pressure sensor connector.

    3. A0138A5

      Connect the glow harness connector.

  37. INSTALL FUEL FILTER ASSEMBLY


    1. A0136XL

      Temporarily install the fuel filter assembly with the 2 bolts and screw.

    2. Tighten the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Using a "torx" socket wrench, tighten the screw.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01393H

      Connect the fuel heater connector.

    5. A013931

      Connect the fuel level warning switch connector.

    6. A0137IZ

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel return hose to the fuel pump return pipe.

    7. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel hose to the fuel pump pipe.

    8. A0135W0

      Connect the pressure control valve connector.

    9. A0135ZW

      Connect the fuel return hose to the No.4 injector.

  38. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A0137UK

      Temporarily install the air cleaner case, air hose No.1 clamp and 2 screws.

    2. Using a "torx" socket wrench, tighten the 2 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Tighten the air hose No.1 clamp.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Connect the PCV hose.

  39. INSTALL TURBO PRESSURE SENSOR


    1. A01362M

      Install the turbo pressure sensor with the bolt.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A0137YA

      Connect the turbo pressure sensor connector.

    3. A0136M9

      Connect the turbo pressure sensor to the cylinder head cover.

  40. INSTALL INTAKE AIR RESONATOR


    1. A0137XK

      Install a new O-ring to the intake air resonator.

    2. Temporarily install the intake air resonator with the clamp, bolt and screw.

    3. Tighten the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    4. Tighten the air hose No.1 clamp.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    5. Using a "torx" socket wrench, tighten the screw.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    6. A0136RX

      Connect the air temperature sensor connector.

  41. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air filter element.

    2. A0136UU

      Using a "torx" socket wrench, install the air cleaner case sub-assembly with the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  42. INSTALL TIMING BELT UPPER COVER


    1. A0138DM

      Install the timing belt upper cover with the 5 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  43. INSTALL ENGINE W/ TRANSAXLE

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