2. |
Remove the drive
belts. |
3. |
Turn the crankshaft and align the white groove
on the crankshaft pulley with the pointer on the lower
cover. |
4. |
Remove the timing
belt. |
5. |
Remove the oil pan(A) and oil
screen.

•
|
Insert the SST between the oil pan
and the ladder frame by tapping it with a plastic hammer
in the direction of
arrow. |
•
|
After tapping the SST with a
plastic hammer along the direction of arrow around more than 2/3 edge
of the oil pan, remove it from the ladder
frame. |
•
|
Do not turn over the SST abruptly
without tapping. It is result in damage of the
SST. | | |
6. |
Remove the front case.

(1) |
Remove the screws(B) from the pump
housing, then separate the housing and cover(A).

|
(2) |
Remove the inner(A) and outer(B)
rotors.

| |
ENGINE OIL AND FILTER
REPLACEMENT |
•
|
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 length and frequency of contact of your skin to 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 used oil filter must be disposed of only at
designated disposal
sites. | |
1. |
Drain engine oil.
(1) |
Remove the oil filter
cap. |
(2) |
Remove the oil drain plug, and drain the
oil into a
container. | |
2. |
Replace oil filter.
(1) |
Remove the oil
filter. |
(2) |
Check and clean the oil filter
installation surface. |
(3) |
Check the part number of the new oil
filter is as same as old one. |
(4) |
Apply clean engine oil to the gasket of
a new oil filter. |
(5) |
Lightly screw the oil filter into place,
and tighten it until the gasket contacts the
seat. |
(6) |
Tighten it an additional 3/4
turn. | |
3. |
Refill with engine oil filter.
(1) |
Clean and install the oil drain plug
with a new gasket.
Tightening torque
39.2 ~ 44.1Nm (4.0 ~ 4.5kgf.m,
28.9 ~ 32.1lb-ft)
| |
(2) |
Fill with fresh engine oil
Capacity
Total : 4.1L (4.33US qts, 3.60lmp
qts)
Oil pan : 3.7L (3.91U.S.qts,
3.26lmp qts)
Drain and refill including oil
filter :
4.0L (4.23U.S.qts, 3.52lmp
qts)
Oil quality : Above API SJ/SL or
SAE 5W-20
| |
(3) |
Install the oil filter
cap. | |
4. |
Start engine and check for oil
leaks. |
5. |
Recheck engine oil
level. |
1. |
Install oil pump.
(1) |
Place the inner and outer rotors into
front case with the marks facing the oil pump cover
side. |
(2) |
Install the oil pump cover(A) to front
case with the 7 screws(B).
Tightenig torque
5.9 ~ 8.8Nm (0.6 ~ 0.9kgf.m, 4.3 ~
6.5lb-ft)
|

| |
2. |
Check that the oil pump turns
freely. |
3. |
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.

Body length
(A) : 25mm (0.98in)
(B) : 20mm (0.787in)
(C) : 38mm (1.496in)
(D) : 45mm (1.771in)
Tighttening
torque
19.6 ~ 26.5Nm (2.0 ~ 2.7kg.m, 14.5 ~
19.8lb-ft)
| |
4. |
Apply a light coat of oil to the seal
lip. |
5. |
Using the SST(09214-33000), install the oil
seal.

|
6. |
Install the oil
screen. |
7. |
Install the oil pan.
Clean the oil pan gasket mating
surfaces. | |
1. |
Remove the relief plunger.
Remove the plug(A), spring(B) and relief
plunger(C).

|
1. |
Inspect relief plunger.
Coat the valve 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. |
2. |
Inspect relief valve spring.
Inspect for distorted or broken relief valve
spring.
Standard
value
Free height : 43.8mm (1.724
in.)
Load : 3.7±0.4kg/40.1mm
(8.14±0.88lb/1.579 in.)
| |
3. |
Inspect rotor side clearance.
Using a feeler gauge and precision straight
edge, measure the clearance between the rotors and precision
straight edge.
Side clearance
|
Outer
gear
|
0.04 ~
0.09mm (0.0016 ~
0.0035in.)
|
Inner
gear
|
0.04 ~
0.085mm (0.0016 ~
0.0033in.)
|

If the side clearance is greater than maximum,
replace the rotors as a set. If necessary, replace the front
case. |
4. |
Inspect rotor tip clearance.
Using a feeler gauge, measure the tip
clearance between the inner and outer rotor tips.
Tip
clearance
0.025 ~ 0.069 mm(0.0010 ~ 0.0027
in.)
|

If the tip clearance is greater than maximum,
replace the rotor as a set. |
5. |
Inspect rotor body clearance.
Using a feeler gauge, measure the clearance
between the outer rotor and body.
Body
clearance
0.12 ~ 0.185 mm(0.0047 ~ 0.0073
in.)
|

If the body clearance is greater than maximum,
replace the rotors as a set. If necessary, replace the front
case. |
1. |
Install relief plunger.
Install relief plunger(A) and spring(B) into
the front case hole, and install the plug(A).
Tightening
torque
39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~
26.2lb-ft)
|

|
1. |
Inspect relief plunger.
Coat the valve 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. |
2. |
Inspect relief valve spring.
Inspect for distorted or broken relief valve
spring.
Standard
value
Free height : 43.8mm (1.724
in.)
Load : 3.7±0.4kg/40.1mm
(8.14±0.88lb/1.579 in.)
| |
3. |
Inspect rotor side clearance.
Using a feeler gauge and precision straight
edge, measure the clearance between the rotors and precision
straight edge.
Side clearance
|
Outer
gear
|
0.04 ~
0.09mm (0.0016 ~
0.0035in.)
|
Inner
gear
|
0.04 ~
0.085mm (0.0016 ~
0.0033in.)
|

If the side clearance is greater than maximum,
replace the rotors as a set. If necessary, replace the front
case. |
4. |
Inspect rotor tip clearance.
Using a feeler gauge, measure the tip
clearance between the inner and outer rotor tips.
Tip
clearance
0.025 ~ 0.069 mm(0.0010 ~ 0.0027
in.)
|

If the tip clearance is greater than maximum,
replace the rotor as a set. |
5. |
Inspect rotor body clearance.
Using a feeler gauge, measure the clearance
between the outer rotor and body.
Body
clearance
0.12 ~ 0.185 mm(0.0047 ~ 0.0073
in.)
|

If the body clearance is greater than maximum,
replace the rotors as a set. If necessary, replace the front
case. | |