For 1990-2009 cars

#### Special Tools

• | KM-6351 Assembly Sleeves

• | KM-J-45000 Remover

### Removal Procedure

1. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement.
2. Remove the oil pan. Refer to Oil Pan Replacement.
3. Remove the generator. Refer to Generator Replacement.
4. Remove the engine damping block, right side. Refer to Engine Mount Replacement - Right Side.
5. Remove the engine damping block support from the cylinder block.

Remove the 3 bolts.

6. Remove the drive belt. Refer to Drive Belt Replacement.
7. Drain the coolant.

• | Place a drip pan underneath.

• | Install the suitable hose to drain port.

• | Open the coolant drain screw (1).

• | Drain the coolant.

• | Close the coolant drain screw.

8. Remove the drive belt tensioner (1).

Remove the bolt (2).

9. Raise the vehicle by its full height.
10. Remove the coolant hose from the coolant pump.

Release the clamp.

11. Detach the coolant pipe (2) from the pump module.

• | Remove the 2 bolts (1).

• | Push the coolant pipe into the oil pump housing adapter.

12. Detach the coolant pipe (3) from the pump module.

• | Detach the coolant pipe from the oil filter housing adapter.

• | Remove the bolt (4).

• | Push the coolant pipe into the oil filter housing adapter.

13. Remove the toothed belt drive gear.

Note: Note different screw lengths.

14. Remove the pump module.

• | Remove the 8 bolts (1, 2).

• | Remove the gasket.

15. Replace the 4 coolant pipe seal rings.

• | Remove the 2 coolant pipes from the oil filter housing adapter.

• | Insert the 2 coolant pipes in the oil filter housing adapter.

16. Clean the sealing surface.

Note: Do not damage the sealing surfaces.

17. Remove the crankshaft seal ring (front) with KM-J-45000 .
18. Remove the oil pump cover (1).

Remove the 6 bolts (2).

### Inspection Procedure

1. Visually inspect the components.

Remove the external rotor with the internal rotor.

2. Inspect the axial clearance of the rotors.

• | Install the external and the internal rotors.

• | Inspect the axial clearance, rotors in respect of the upper edge of the control unit housing.

• | Permissible measurement: 0.02-0.058 mm.

### Installation Procedure

1. Clean the sealing surface.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the oil pump cover.

Tighten
Tighten the 6 bolts to 8 N·m (71 lb in).

Note: Note different screw lengths.

3. Install the pump module.

• | Replace the gasket.

• | Tighten the 8 bolts.

Tighten
Tighten the 8 bolts to 20 N·m (15 lb ft).

• | Insert the toothed belt drive gear.

4. Install the coolant pipe to the coolant module.

• | Pull the coolant pipe out of the oil filter housing adapter.

• | Install the coolant pipe to the oil filter housing adapter.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

5. Install the coolant pipe to the coolant module.

Pull the coolant pipe out of the oil pump housing adapter.

Tighten
Tighten the 2 bolts to 9 N·m (80 lb in).

6. Install the front crankshaft seal ring (1).

• | Clean the sealing surfaces.

• | Slide the protective sleeve of KM-6351 (2) onto the crankshaft journal.

• | Slide the seal ring over the protective sleeve on the crankshaft journal.

7. Clean the thread, drive belt tensioner.
8. Intake the drive belt tensioner.

• | Insert the drive belt tension roller.

• | Use a new bolt.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

• | Released leg of spring (1) of the drive belt tension roller must engage in the cut-out (arrow) of the pump module.

9. Lower the vehicle by its full height.
10. Install the drive belt. Refer to Drive Belt Replacement.
11. Install the support for the engine damping block.

Tighten
Tighten the 3 bolts to 50 N·m (37 lb ft).

12. Install the right engine damping block. Refer to Engine Mount Replacement - Right Side.
13. Install the oil pan. Refer to Oil Pan Replacement.
14. Install the generator. Refer to Generator Replacement.
15. Connect the battery.

Connect the ground connection to the negative terminal.

Tighten
Tighten the nut to 5 N·m (44 lb in).

16. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling.
17. For programming procedures, refer to Control Module References.
18. Close the hood.