SECTION 6F - ENGINE LUBRICATION (6VD1 MODELS)
Service Precaution
General Description
Oil Pump
Oil Pump and Associated Parts
Disassembly
Inspection and Repair
Reassembly
Oil Pan and Crankcase
Removal
Installation
Oil Pump
Removal
Installation
Oil Pump Oil Seal
Removal
Installation
Main Data and Specification
Service Precaution
WARNING: THIS VEHICLE HAS 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
replacement after removal. holden 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
C06RW003
Legend
(1) Oil Strainer
(2) Oil Pump
(3) Relief Valve
(4) Oil Pressure Switch
(5) Oil Filter
(6) Safety Valve
(7) Oil Gallery
(8) Crankshaft Bearing
(9) Crankshaft
(10) Connecting Rod Bearing
(11) Connecting Rod
(12) Piston
(13) Oil Gallery; Cylinder Head
(14) Camshaft
(15) Camshaft Journal
(16) Front Journal; Camshaft Drive Gear
(17) Rear Journal; Camshaft Drive Gear
(18) Oil Pan
Oil Pump
Oil Pump and Associated Parts
051RW005
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
Disassembly
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.
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)
DCheck to see that the relief valve slides freely.
DThe oil pump must be replaced if the relief valve does
not slide freely.
DReplace 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.
DBadly worn or damaged driven gear (10).
DBadly worn drive gear (11) driving face.
DBadly scratched or scored body sliding face (14) or
driven gear (10).
DBadly 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
DMeasure 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
DMeasure 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).
DCarefully 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. T ake
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
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.
DAttach oil pump assembly to cylinder body.
DTighten the oil pump fixing bolts.
Torque : 25 N·m (2.6 kg·m/18 lb·ft)
051RW002
051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
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 (2.6 kg·m/18 lb ft)
10.Install oil pipe (3) with O-ring (13).
Torque: 25 N·m (2.6 kg·m/18 lb ft)
11.Install crankcase with oil pan (2).
DRemove oil on crankcase mounting surface and dry
the surface.
DApply 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.
DThe crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
DTighten fixing bolts to the specified torque.
Torque : 10 N·m (1.0 kg·m/89 lb in)
013RW010
12.Install crankshaft timing pulley.
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 dam-
aged.
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.
DThe 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.
DThe 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
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.
D Refer to removal procedure for Oil Pan and
Crankcase in this section.
4.Remove crankshaft pulley.
DRefer to removal procedure for Crankshaft Pulley in
this service information.
5.Remove timing belt.
DRefer to removal procedure for Timing Belt in this
service infromation.
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
DApply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
DThe 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
DUse 5–8840–2287–0 installer when installing new
oil seal.
DApply engine oil to oil seal lip.
DInstall oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001
DTighten 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
Legend
(1)Oil Pump
(2)Oil Filter
(3)Oil Gallery
(4)From Oil Filter
(5)To Oil Filter
5.Install timing pulley on crankshaft.
Install timing belt.
DRefer to installation procedure for Timing Belt in this
service information.
6.Install crankshaft pulley.
DRefer to install procedure for Crankshaft Pulley in
this service information.
7.Install crankcase assembly.
DRefer to installation procedure for Oil Pan and
Crankcase in this section.
8.Refill engine oil until full level on engine oil dipstick.
Oil Pump Oil Seal
Removal
1.Disconnect battery ground cable.
2.Drain engine oil.
3.Remove crankshaft pulley.
DRefer to removal procedure for Crankshaft Pulley in
this service information.
4.Remove timing belt.
DRefer to removal procedure for Timing Belt in this
information.
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.
DRefer to installation procedure for Timing Belt in this
service information.
4.Install crankshaft pulley.
DRefer to installation procedure for Crankshaft
Pulley in this service information.
5.Refill engine oil until full level.
Main Data and Specification
General Specification
Item
Specifications
Item
6VD1
Oil capacity 5.3 liters
Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
N·m (kg·m/ lb·ft)
E06RW045