2.
Disconnect the rear oxygen sensor connector(A).
Drain the engine oil.
Disconnect the rear oxygen sensor connector(A).
Remove the front muffler(B).
Remove the exhaust manifold and catalytic converter assembly(A).
Using the SST(09215-3C000) and remove the oil pan.
Drain the engine oil.
Remove the drive belts.
Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
Remove the timing belt.
Remove the timing belt tensioner(A).
Remove the oil pan and oil screen.
Remove the alternator. (Refer to EE group - alternator)
Remove the air conditioner compressor tensioner bracket(A).
Remove the front case.
Remove the screw from the pump housing, then separate the housing and cover(A).
Remove the inner rotor(A) and outer rotor(B).
Install the oil pump.
Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
Install the oil pump cover(A) to front case with the 7 screws.
Tightening torque :
5.9 ~ 6.9N.m (0.6 ~ 0.7kgf.m, 4.3 ~ 5.1lb-ft)
Check that the oil pump turns freely.
Install the oil pump on the cylinder block.
Place a new front case gasket on the cylinder block.
Apply engine oil to the lip of the oil pump seal. Then, install the oil pump onto the crankshaft.
When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
Bolt length
(A) : 30mm (1.181in), (B) : 22mm (0.866in),
(C) : 45mm (1.772in), (D) : 60mm (2.362in)
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Apply a light coat of oil to the front case oil seal lip.
Using the SST(09214-32000),install the front case oil seal.
Install the air conditioner compressor tensioner bracket (A).
Install the alternator. (Refer to EE group - alternator)
Install the oil screen.
Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
Install the oil pan.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Clean the oil pan gasket mating surfaces.
Install the timing belt tensioner.
Install the timing belt.
Install the drive belts.
Fill with engine oil.
Install the oil pan.
Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
Check that the mating surfaces are clean and dry before applying liquid gasket.
Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket : MS 721-40A or equivalent
To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the residue.
After assembly, wait at least 30 minutes before filling the engine with oil.
Install the oil pan(A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the exhaust manifold and catalytic converter assembly(A).
Install the front muffler(B).
Tightening torque :
29.4 ~ 39.2N.m (3.0 ~ 4.0kgf.m, 21.7 ~ 28.9lb-ft)
Connect the rear oxygen sensor connector(A).
Fill with engine oil.
Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).
Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
Inspect the relief valve spring.
Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.6mm (1.8346in)
Load : 6.1±0.4kg/40.1mm (13.4±0.9 lb/1.5787in)
Inspect the rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
Side clearance | Inner rotor | 0.04 ~ 0.085mm (0.0016 ~ 0.0033in) |
Outer rotor | 0.04 ~ 0.09mm (0.0016 ~ 0.0035in) |
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
Inspect the rotor tip clearance.
Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips.
Tip clearance
0.025 ~ 0.069mm (0.0010 ~ 0.0027in)
If the tip clearance is greater than specified, replace the rotors as a set.
Inspect the rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
Body clearance
0.060 ~ 0.090mm (0.0024 ~ 0.0035in)
If the body clearance is greater than specified, replace the rotors as a set. If necessary, replace the front case.
Install the relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
