Front Engine Plate: Service and Repair

DISASSEMBLY
1. Remove the timing belt.
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen.
5. Remove the front case assembly.
6. Remove the oil pump cover.





7. Remove the inner and outer gears from the front case. The mating marks on the inner and outer gears indicate the direction of installation. Make sure that the inner and outer gears are installed as shown.
8. Remove the plug and remove the relief spring and relief plunger.

INSPECTION

Front Case
1. Check the front case for cracks or damage. Replace as necessary.
2. Check the front oil seal for worn or damaged lips. Replace if defective.

Oil Pan And Oil Screen
1. Check the oil pan for failure, damage or cracks. Replace if defective.
2. Check the oil screen for failure, damage and cracks and replace if defective.

Front Case And Oil Pump Cover
Worn (especially stepped) or damaged surfaces contacting gears.

Relief Valve And Spring
1. Check sliding condition of the relief valve inserted in the front case.
2. Inspect for distorted or broken relief valve spring.
Free height: 46.6 mm (1.835 inch)
Load: 6.1 kg/40.1 mm (13.4 lbs/1.579 inch)

Oil Pump Gears
1. Worn or damaged gear teeth surfaces.





2. Clearance between outer gear and front case.
Outer gear:
Clearance between outer circumference and front case: 0.12-0.18 mm (0.005-0.007 inch)





3. Check the tip clearance on the pump rotor
Standard value: 0.025-0.069 mm (0.0001-0.003 inch)








4. Check the axial clearance on the outer pump rotor
Standard value: 0.04-0.087 mm (0.0016-0.0034 inch)

REASSEMBLY

Front Case





Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Standard value:
(A): 25 mm (0.98 inch)
(B): 30 mm (1.18 inch)
(C): 45 mm (1.77 inch)
(D): 60 mm (2.36 inch)

Oil Seal
1. Inspect for worn, distorted or damaged lips.
2. Check for elongated spring ring.





3. Install Special Tool, Crankshaft Front Oil Seal Guide (09231-22100), to the front end of the crankshaft. Apply engine oil to the outer surface of the oil seal guide, and install the new oil seal along the guide by hand, until it touches front case. Always use a new oil seal when reassembling.





4. Use Special Tool, Crankshaft Front Oil Seal Installer (09231-22000), to install the oil seal.
5. Install the crankshaft sprocket, timing belt and crankshaft pulley. Refer to "Timing Belt".
6. Install the oil screen.
7. Clean both gasket surfaces of the oil pan and the cylinder block.





8. Apply sealant into the groove of the oil pan flange as shown.

CAUTION:
1) Apply sealant approx. 4 mm (0.16 inch) in thickness.
2) After application of sealant, do not exceed 15 minutes before installing the oil pan.

9. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque:
Oil Pan bolt: 6-8 Nm (60-80 kg.cm, 4-6 ft. lbs.)

Oil Pump





1. Install the outer and inner gears into the front case. Make sure that the inner and outer gears are installed in the same direction as shown.
2. Install the oil pump cover and tighten the bolts to the specified torque. After the bolts have been tightened, check to ensure that the gear turns smoothly.
Tightening torque:
Oil pump cover bolt: 6-9 Nm (60-90 kg.cm, 4.5-6.6 ft. lbs.)
3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.
Tightening torque:
Relief valve plug: 40-50 Nm (400-500 kg.cm, 29-36 ft. lbs.)