SERVICE 6G1 - ENGINE LUBRICATION

Service Precaution

General Description

Oil Pump

Oil Pump and Associated Parts

Removal

Inspection and Repair

Reassembly

Oil Pan and Crankcase

Removal

Installation

Oil Pump

Removal

Installation

Oil Pump Oil Seal

Removal

Installation

Oil Filter

Removal

Installation

Main Data and Specification

Special Tool

Service Precaution

WARNING: IF SO EQUIPPED WITH A

SUPPLEMENTAL RESTRAINT SYSTEM (SRS),

REFER TO THE SRS COMPONENT AND WIRING

LOCATION VIEW IN ORDER TO DETERMINE

WHETHER YOU ARE PERFORMING SERVICE ON

OR NEAR THE SRS COMPONENTS OR THE SRS

WIRING. WHEN YOU ARE PERFORMING SERVICE

ON OR NEAR THE SRS COMPONENTS OR THE SRS

WIRING, REFER TO THE SRS SERVICE

INFORMATION. FAILURE TO FOLLOW WARNINGS

COULD RESULT IN POSSIBLE AIR BAG

DEPLOYMENT, PERSONAL INJURY, OR

OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. IHOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the

correct tightening sequence and specifications.

Following these instructions can help you avoid

damage to parts and systems.

Techline

General Description

C06RW002

EndOFCallout

Legend

(1) Oil Strainer

(2) Oil Pump

(3) Relief Valve

(4) Oil Pressure Switch

(5) Oil Filter

(6) Safety Valve

(7) Oil Pressure Unit

(8) Oil Gallery

(9) Crankshaft Bearing

(10) Crankshaft

(11) Connecting Rod Bearing

(12) Connecting Rod

(13) Piston

(14) Oil Gallery; Cylinder Head

(15) Camshaft

(16) Camshaft Journal

(17) Front Journal; Camshaft Drive Gear

(18) Rear Journal; Camshaft Drive Gear

(19) Oil Pan

Oil Pump

Oil Pump and Associated Parts

051RW005

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Removal

1. Remove crankshaft timing pulley.

2. Remove crankcase with oil pan.

3. Remove oil pipe.

4. Remove oil strainer.

5. Remove oil pump assembly.

6. Remove plug.

7. Remove spring.

8. Remove relief valve.

9. Remove oil pump cover.

10. Remove driven gear.

11. Remove drive gear.

12. Remove oil seal.

13. Remove O-ring.

Legend

(1) Crankshaft Timing Pulley

(2) Crankcase with Oil Pan

(3) Oil Pipe

(4) Oil Strainer

(5) Oil Pump Assembly

(6) Plug

(7) Spring

(8) Relief Valve

(9) Oil Pump Cover

(10) Driven Gear

(11) Drive Gear

(12) Oil Seal

(13) O-ring

(14) Oil Pump Body

Inspection and Repair

CAUTION: Make necessary correction or parts

replacement if wear, damage or any other abnormal

conditions are found during inspection.

Relief Valve (8)

• Check to see that the relief valve slides freely.

• The oil pump must be replaced if the relief valve does

not slide freely.

• Replace the spring and/or the oil pump assembly (5)

if the spring is damaged or badly worn.

051RS002

Body (14) and Gears (10, 11)

The pump assembly must be replaced if one or more of

the conditions below is discovered during inspection.

• Badly worn or damaged driven gear (10).

• Badly worn drive gear (11) driving face.

• Badly scratched or scored body sliding face (14) or

driven gear (10).

• Badly worn or damaged gear teeth.

Measure the clearance between the body and the

driven gear with a feeler gauge.

Standard : 0.10 mm–0.18 mm

(0.0039 in.–0.0070 in)

Limit : 0.20mm (0.0079 in)

051RS004

• Measure the clearance between the drive gear and

driven gear with a feeler gauge.

Standard : 0.11 mm–0.24 mm

(0.0043 in–0.0094 in)

Limit : 0.35mm (0.0138 in)

051RS003

• Measure the side clearance with a precision straight

edge and a feeler gauge.

Clearance

Standard : 0.03 mm–0.09 mm

(0.0011 in–0.0035 in)

Limit : 0.15mm (0.0059 in)

051RS005

Oil Strainer

Check the oil strainer for cracking and scoring. If

cracking and scoring are found, the oil strainer must be

replaced.

051RS006

Reassembly

1.Install drive gear (11).

2.Install driven gear (10).

3.Install oil pump cover (9) and first, loosely tighten all

of the attaching screws. Next, tighten the attaching

screws to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

After installation, check that the gear rotates

smoothly.

4.Install relief valve (8) and apply engine oil to the

relief valve and spring (7).

5.Install spring (7).

6.Install the plug (6).

Torque : 8 N·m (0.8 Kg·m/69 lb in)

051RS007

7.Install oil pump assembly (5).

•Carefully remove any oil from the cylinder body

and the pump. Apply sealant (TB–1207B or

equivalent) to the pump fitting face as shown in

illustration. Take care that sealant is not applied

to oil port surfaces. The oil pump assembly must

be installed within 5 minutes after sealant

application before the sealant hardens.

CAUTION: Do not apply an excessive amount of

sealant to the contact surface. Applying too much

sealant will overflow the contact surfaces. This

could cause serious damage to the engine.

• Attach oil pump assembly to cylinder body.

• Tighten the oil pump fixing bolts.

Torque : 25 N·m (2.5 Kg·m/18 lb·ft)

051RW002

051RW001

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8. Install the new oil seal (12). Apply engine oil to the

oil seal lip before installation then use 5–8840–

2287–0 oil seal Installer, install oil seal.

015RS001

9. Install oil strainer (4) with O-ring (13).

Torque: 25 N·m (2.5 Kg·m/18 lb ft)

10. Install oil pipe (3) with O-ring (13).

Torque: 25 N·m (2.5 Kg·m/18 lb ft)

11. Install crankcase with oil pan (2).

• Remove oil on crankcase mounting surface and

dry the surface.

• Apply a proper 4.5 mm (0.7 in) wide bead of

sealant (TB1207C or equivalent) to the

crankcase mounting surface. The bead must be

continuous.

• The crankcase must be installed within 5 minutes

after sealant application before the sealant

hardens.

• Tighten fixing bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

013RW010

12. Install crankshaft timing pulley.

Legend

(1) Around Bolt Holes

(2) Around Dowel Pin

Oil Pan and Crankcase

Removal

1. Disconnect battery ground cable.

2. Drain engine oil.

3. Lift vehicle by supporting the frame.

4. Remove front wheels.

5. Remove oil level dipstick from level gauge tube.

6. Remove stone guard.

7. Remove radiator under fan shroud.

8. Remove suspension cross member fixing bolts, 2

pcs each per side and remove suspension cross

member.

9. Remove pitman arm and relay lever assembly,

using the 5–8840–2005–0 remover, remove pitman

arm from the steering unit and remove four fixing

bolts for relay lever assembly.

10. Remove axle housing assembly four fixing bolts

from housing isolator side and mounting bolts from

wheel side. At this time support the axle with a

garage jack and remove axle housing assembly.

11. Remove oil pan fixing bolts.

12. Remove oil pan, using 5–8840–2153–0 sealer

cutter, remove oil pan.

013RS003

13. Remove crankcase fixing bolts.

14. Remove crankcase, using 5–8840–2153–0 sealer

cutter, remove crankcase.

NOTE: Do not deform or damage the flange of oil pan

and crankcase.

Replace the oil pan and/or crankcase if deformed or

damaged.

013RS003

Installation

1. Install crankcase.

1. Remove residual sealant, lubricant and moisture

from mounting surface, then dry thoroughly.

2. Properly apply a 4.5 mm (0.7 in) wide bead of

sealant (TB-1207C or equivalent) to mounting

surface of crankcase.

Sealant beat must be continuous.

• The crankcase must be installed within 5

minutes after sealant application before the

sealant hardens.

013RW010

3. Install crankcase, tighten crankcase fixing bolts

to the specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

013RW004

2. Install oil pan

1. Remove residual sealant, lubricant and moisture

from mounting surface, then dry thoroughly.

2. Properly apply a 4.5 mm (07 in) wide bead of

sealant (TB-1207C or equivalent) to mounting

surface of oil pan.

Sealant beat must be continuous.

• The crankcase must be installed within 5

minutes after sealant application befor the

sealant hardens.

013RW003

3. Install oil pan, tighten oil pan fixing bolts to the

specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

3. Install axle housing assembly and tighten fixing

bolts to the specified torque.

Axle case bolts

Torque : 82 N·m (8.4 Kg·m/60 lb ft)

Mounting bolts

Torque : 152 N·m (15.5 Kg·m/112 lb ft)

013RW005

4. Install relay lever assembly and tighten fixing bolts.

Torque: 44 N·m (4.5 Kg·m/32 lb ft)

5. Engage teeth of pitman arm and steering unit, and

tighten nut to the specified torque.

Torque : 216 N·m (22.0 Kg·m/159 lb ft)

013RW006

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Legend

(1) Pitman Arm

(2) Relay Lever

6. Install suspension cross member and tighten fixing

bolts to the specified torque.

Torque : 78 N·m (8.0 Kg·m/58 lb ft)

013RW007

7. Install radiator under fan shroud.

8. Install stone guard.

9. Install engine oil level dipstick.

10. Fill engine oil until full level on engine oil gauge

dipstick.

Oil Pump

Removal

1.Disconnect battery ground cable.

2.Drain engine oil.

3.Remove crankcase assembly.

• Refer to removal procedure for Oil Pan and

Crankcase in this manual.

4.Remove crankshaft pulley.

•Refer to removal procedure for Crankshaft Pulley

in this manual.

5. Remove timing belt.

•Refer to removal procedure for Timing Belt in this

manual.

6. Remove timing pulley from crankshaft.

7. Remove four fixing bolts from oil filter assembly.

8. Remove oil strainer fixing bolts, remove oil strainer

assembly with O-ring.

9. Remove three bolts from oil pipe and O-ring.

10. Remove eight oil pump fixing bolts, then oil pump

assembly.

11. Remove sealant from mounting surface of oil pump

assembly, cylinder block and take care not to

damage mounting surfaces of oil pump and cylinder

block.

Installation

1. Install oil pump assembly

• Apply sealant (TB-1207B or equivalent) to the oil

pump mounting surfaces as shown in the

illustration.

• The oil pump assembly must be installed within 5

minutes after sealant application before the

sealant hardens.

NOTE: Do not apply sealant to the oil ports.

051RW002

• Use 5–8840–2287–0 installer when installing new

oil seal.

• Apply engine oil to oil seal lip.

• Install oil pump assembly to the cylinder block.

NOTE: Do not damage oil seal during installation of oil

pump assembly.

015RS001

• Tighten fixing bolts to the specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

051RW001

2. Install oil pipe with O-ring, tighten fixing bolt to the

specified torque.

Torque : 10 N·m (1.0 Kg·m/89 lb in)

3. Install oil strainer with O-ring, tighten fixing bolt to

the specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

4.Install oil filter assembly and tighten bolts to the

specified torque.

Torque : 25 N·m (2.5 Kg·m/18 lb ft)

050RW001

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5.Install timing pulley on crankshaft.

Install timing belt.

•Refer to installation procedure for Timing Belt in

this manual.

6.Install crankshaft pulley.

•Refer to install procedure for Crankshaft Pulley in

this manual.

7. Install crankcase assembly.

•Refer to installation procedure for Oil Pan and

Crankcase in this manual.

8. Refill engine oil until full level on engine oil dipstick.

Legend

(1) Oil Pump

(2) Oil Filter

(3) Oil Gallery

(4) From Oil Filter

(5) To Oil Filter

Oil Pump Oil Seal

Removal

1.Disconnect battery ground cable.

2.Drain engine oil.

3.Remove crankshaft pulley.

•Refer to removal procedure for Crankshaft Pulley

in this manual.

4. Remove timing belt.

•Refer to removal procedure for Timing Belt in this

manual.

5. Remove timing pulley from crankshaft.

6. Remove oil pump oil seal using a sealer puller.

NOTE: Take care not to damage sealing surfaces of oil

pump and crankshaft when removing oil seal.

Installation

1. Install oil pump oil seal, apply engine oil to oil seal

lip, then install oil seal using 5–8840–2287–0

installer.

015RS001

2. Install timing pulley to crankshaft.

3. Install timing belt.

•Refer to installation procedure for Timing Belt in

this manual.

4. Install crankshaft pulley.

•Refer to installation procedure for Crankshaft

Pulley in this manual.

5. Refill engine oil until full level.

Oil Filter

Removal

1. Disconnect battery ground cable.

2. Drain engine oil.

3. Remove oil filter using 5-8840-0203-0 filter wrench.

Installation

1. Clean filter fitting surface and apply small amount of

engine oil to sealing surface.

2. Install oil filter cartridge by hand until it comes in

contact with sealing surface then rotate additional 2/

3 turn to tighten using 5-8840-0203-0 filter wrench.

050RW001

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3. Fill engine oil until full level on dipstick.

4. Reconnect battery ground cable.

Legend

(1) Oil Pump

(2) Oil Filter

(3) Oil Gallery

(4) From Filter

(5) To Filter

Main Data and Specification

General Specification

Torque Specifications

Crankcase, Oil pan, Timing belt tensioner, Timing

pulley, timing belt cover, Oil pump, Oil gallery, Oil

strainer N·m (Kg·m/lbft)

E06RW045

Item Specification

Oil capacity - 5.3 liters

Special Tool

ILLUSTRATION TOOL NO.

TOOL NAME

5–8840–2287–0

(J–39202)

Installer; Oil pump oil seal

5–8840–2153–0

(J–37228)

Seal cutter

5–8840–2005–0

(J–29107)

Universal pitman arm

puller

5–8840–0203–0

(J–36390)

Wrench; Oil filter