REPLACEMENT
| CAUTION | Prolonged and repeated contact with engine oil will cause removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use a waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners or solvents. For environmental protection, used oil and used oil filters must be disposed of at designated disposal sites. |
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- REMOVE ENGINE UNDER COVER RH
- DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug and drain the oil into a container. Clean and install the oil drain plug with a new gasket. Torque: 37 N.m (377 Kgf.cm, 27 ft.lbf)
- REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter SST 09228-06501
- INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, then tighten it until the gasket comes into contact with the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-06501 Reference Torque: 13 N.m (133 Kgf.cm, 10 ft.lbf)
- ADD ENGINE OIL Fill with fresh engine oil. Capacity: ENGINE OIL CAPACITY SPECIFICATION Drain and refill with oil filter change 3.7 liters (3.9 US qts, 3.3 Imp. qts) Drain and refill without oil filter change 3.5 liters (3.7 US qts, 3.1 Imp. qts) Dry fill 4.2 liters (4.4 US qts, 3.7 Imp. qts)
- CHECK FOR ENGINE OIL LEAKAGE
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- CHECK ENGINE OIL LEVEL Warm up the engine, then stop the engine and wait for 5 minutes. Check that the engine oil level is between the L and F marks on the level gage. If low, check for leakage and top oil up to the F mark. NOTE: Do not add engine oil to above the F mark.
- CHECK ENGINE OIL QUALITY Check the oil for deterioration, water intrusion, discoloration or thinning. If the quality is visibly poor, replace the oil. Oil grade: Use API grade SL "Energy-Conserving", or ILSAC multigrade engine oil. SAE 5W-30 is the best choice for good fuel economy, and good starting in cold weather. If SAE 5W-30 is not available, SAE 10W-30 may be used. However, it should be replaced with SAE 5W-30 at the next oil replacement.
- INSPECT OIL PRESSURE Disconnect the oil pressure switch connector. Using a 24 mm deep socket wrench, remove the oil pressure switch. Install the oil pressure gauge. Warm up the engine. Check the oil pressure. Oil pressure: OIL PRESSURE SPECIFICATION When idling 39.2 kPa (0.4 kgf/cm 2 , 5.7 psi) or more At 3,000 RPM 294 to 539 kPa (3.0 to 5.5 kgf/cm 2 , 43 to 78 psi) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N.m (153 Kgf.cm, 11 ft.lbf) NOTE: Do not start the engine for at least 1 hour after installation. Connect the oil pressure switch connector. Check for engine oil leakage.
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- DISCONNECT BATTERY NEGATIVE TERMINAL
- DRAIN COOLANT (See «ENGINE COOLANT (1ZZ-FE)»(ref-225496-S15766401382006031900000) )
- DRAIN ENGINE OIL Remove the oil pan drain plug, then drain the engine oil.
- INSTALL OIL PAN DRAIN PLUG Clean and install the oil pan drain plug with a new gasket. Torque: 37 N.m (377 Kgf.cm, 27 ft.lbf)
- REMOVE FRONT WHEEL RH
- REMOVE ENGINE UNDER COVER RH
- REMOVE FRONT SUSPENSION BAR ASSY TOWER (See «FRONT SUSPENSION BAR ASSY TOWER»(ref-225500-S19574127682006031900000) )
- REMOVE CYLINDER HEAD COVER NO. 2 Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
- REMOVE WIRE HARNESS PROTECTOR (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- SEPARATE SUCTION HOSE SUB-ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
- REMOVE FAN AND GENERATOR V BELT (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
- REMOVE GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
- REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See «REPLACEMENT»(ref-225511-S01650403452006031900000) ) HINT: Hang up the hoses instead of detaching.
- REMOVE SHIFT LEVER KNOB SUB-ASSY
- REMOVE CONSOLE PANEL UPPER (See «REPLACEMENT»(ref-225519-S37374870712006031900000) )
- REMOVE PARKING BRAKE HOLE COVER SUB-ASSY (See «REPLACEMENT»(ref-225519-S37374870712006031900000) )
- REMOVE CONSOLE BOX CARPET
- REMOVE CONSOLE BOX SUB-ASSY REAR (See «REPLACEMENT»(ref-225519-S37374870712006031900000) )
- REMOVE EXHAUST PIPE ASSY FRONT (See «REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY»(ref-225495-S04576187502006031900000) )
- REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE V-RIBBED BELT TENSIONER ASSY HINT: Jack the engine up and down to remove the bolt.
- REMOVE IGNITION COIL ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE MANIFOLD STAY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE EXHAUST MANIFOLD (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE WATER PUMP PULLEY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09960-10010 (09962-01000, 09963-00600)
- REMOVE WATER PUMP ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE TRANSVERSE ENGINE MOUNTING BRACKET (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE CRANKSHAFT POSITION SENSOR
- SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09213-70011 (09213-70020), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)
- REMOVE CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE TIMING CHAIN OR BELT COVER OIL SEAL (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
- REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and chain tensioner slipper.
- REMOVE CHAIN VIBRATION DAMPER NO. 1 Remove the 2 bolts and chain vibration damper No. 1.
- REMOVE CHAIN SUB-ASSY
- REMOVE OIL PUMP ASSY Remove the 5 bolts, then remove the oil pump. Remove the gasket from the cylinder block.
- INSTALL OIL PUMP ASSY Place a new gasket on the cylinder block. Align the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, then slide on the oil pump. Install the oil pump with the 5 bolts. Torque: 9.0 N.m (92 Kgf.cm, 80 in. lbf)
- INSTALL CHAIN VIBRATION DAMPER NO. 1 Install the chain vibration damper No. 1 with the 2 bolts. Torque: 21 N.m (214 Kgf.cm, 15ft. lbf)
- INSTALL CHAIN SUB-ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09223-22010
- INSTALL CHAIN TENSIONER SLIPPER (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1 (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL TIMING CHAIN OR BELT COVER OIL SEAL (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09223-22010
- INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
- INSTALL CHAIN TENSIONER ASSY NO. 1 (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL CRANKSHAFT PULLEY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09213-70011 (09213-70020), 09330-00021
- INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N.m (92 Kgf.cm, 80 in. lbf)
- INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL WATER PUMP ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL WATER PUMP PULLEY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) ) SST 09960-10010 (09962-01000, 09963-00600)
- INSTALL EXHAUST MANIFOLD (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 Torque: 20 N.m (204 Kgf.cm, 15 ft.lbf)
- INSTALL MANIFOLD STAY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL CYLINDER HEAD COVER SUB-ASSY (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL IGNITION COIL ASSY Torque: 9.0 N.m (92 Kgf.cm, 80 in. lbf)
- INSTALL V-RIBBED BELT TENSIONER ASSY Torque: 29 N.m (296 Kgf.cm, 21 ft. lbf) for nut 100 N.m (1,020.Kgf.cm, 74 ft. lbf) for bolt
- INSTALL ENGINE MOUNTING INSULATOR SUB-ASSY RH (See «REPLACEMENT»(ref-225494-S31311650312006031900000) )
- INSTALL EXHAUST PIPE ASSY FRONT (See «REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY»(ref-225495-S04576187502006031900000) )
- INSTALL CONSOLE BOX SUB-ASSY REAR
- INSTALL CONSOLE BOX CARPET
- INSTALL PARKING BRAKE HOLE COVER SUB-ASSY
- INSTALL CONSOLE PANEL UPPER
- INSTALL SHIFT LEVER KNOB SUB-ASSY
- INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See «REPLACEMENT»(ref-225511-S01650403452006031900000) )
- INSTALL GENERATOR ASSY (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
- INSTALL GENERATOR BRACKET NO. 1 (See «REPLACEMENT»(ref-225499-S01934306782006031900000) )
- INSTALL SUCTION HOSE SUB-ASSY Torque: 9.8 N.m (100 Kgf.cm, 87 in. lbf)
- INSTALL AIR SWITCHING VALVE ASSY (See «AIR SWITCHING VALVE ASSY (2ZZ-GE)»(ref-225493-S14758346662006031900000) )
- INSTALL CYLINDER HEAD COVER NO. 2 Torque: 7.0 N.m (71 Kgf.cm, 62 in. lbf)
- INSTALL FRONT SUSPENSION BAR ASSY TOWER (See «FRONT SUSPENSION BAR ASSY TOWER»(ref-225500-S19574127682006031900000) )
- INSTALL FRONT WHEEL RH Torque: 103 N.m (1,050 Kgf.cm, 76 ft.lbf)
- CONNECT BATTERY NEGATIVE TERMINAL
- ADD COOLANT (See «ENGINE COOLANT (1ZZ-FE)»(ref-225496-S15766401382006031900000) )
- ADD ENGINE OIL (See «OIL FILTER SUB-ASSY (2ZZ-GE)»(ref-225497-S40102443022006031900000) )
- CHECK FOR ENGINE COOLANT LEAKAGE (See «ENGINE COOLANT (1ZZ-FE)»(ref-225496-S15766401382006031900000) )
- CHECK FOR ENGINE OIL LEAKAGE
- CHECK FOR EXHAUST GAS LEAKAGE
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- REMOVE OIL PUMP RELIEF VALVE Using a 28 mm socket wrench, remove the oil pump relief valve plug. Remove the oil pump relief valve spring and oil pump relief valve. Oil pump relief valve spring Oil pump relief valve
- INSPECT OIL PUMP ASSY Remove the 5 screws and oil pump cover. Check the oil pump relief valve. Coat the valve with engine oil, then check that it falls smoothly into the valve hole by its own weight. Check the oil pump rotor. Coat the oil pump gear set with engine oil, then place it into the oil pump body. Check that the rotor revolves smoothly. Check the rotor tip clearance. Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) Check the body clearance. Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.125 to 0.180 mm (0.0049 to 0.0071 in.) Maximum body clearance: 0.325 mm (0.0128 in.) Check the rotor side clearance. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 to 0.080 mm (0.0012 to 0.0032 in.) Maximum side clearance: 0.16 mm (0.0063 in.) Install the oil pump rotor. Coat the oil pump gear set with engine oil, then place it into the oil pump body with the marks facing the pump body cover side. Install the oil pump cover with 5 screws. Torque: 10 N.m (105 Kgf.cm, 8 ft. lbf)
- INSTALL OIL PUMP RELIEF VALVE Install the oil pump relief valve spring and oil pump relief valve. Oil pump relief valve spring Oil pump relief valve Using a 28 mm socket wrench, install the oil pump relief valve plug. Torque: 49 N.m (500 Kgf.cm, 36 ft.lbf)
| CAUTION | 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. Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents. For environmental protection, used oil and used oil filters must be disposed of only at designated disposal sites. |
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- REMOVE ENGINE UNDER COVER RH
- DRAIN ENGINE OIL Remove the oil pan drain plug and drain the engine oil.
- REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter SST 09228-06501
- INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket comes into contact with the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-06501 Reference torque: 13 N.m (133 Kgf.cm, 10 ft.lbf)
- INSTALL OIL PAN DRAIN PLUG Clean and install the oil pan drain plug with a new gasket. Torque: 37 N.m (377 Kgf.cm, 27 ft.lbf)
- ADD ENGINE OIL Fill with fresh engine oil. Capacity: ENGINE OIL CAPACITY SPECIFICATION Drain and refill with oil filter change 4.4 liters (4.7 US qts, 3.9 Imp. qts) Drain and refill without oil filter change 4.2 liters (4.4 US qts, 3.7 Imp. qts) Dry fill 4.8 liters (5.1 US qts, 4.2 Imp. qts)
- CHECK FOR ENGINE OIL LEAKAGE