Removal and Installation

OIL PUMP

COMPONENTS:

REMOVAL
1. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
a. Remove the engine and transmission.
2. REMOVE TIMING BELT
a. Remove the timing belt.
3. REMOVE CRANKSHAFT TIMING PULLEY

4. REMOVE OIL DIPSTICK GUIDE
a. Remove the bolt and dipstick guide.
b. Pull out the dipstick guide together with the dipstick from the No. 1 oil pan.
c. Pull the O-ring from the dipstick guide.
5. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Disconnect the oil pressure switch connector.
b. Disconnect the oil cooler hose from the oil cooler.
c. Remove the 2 bolts, nut, compressor stay, oil cooler and filter bracket assembly.
d. Remove the gasket from the filter bracket.
6. REMOVE CRANKSHAFT POSITION SENSOR

7. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
a. Remove the 20 bolts and 2 nuts.
b. Insert the blade of SST between the No. 1 and No. 2 oil pans, cut off applied sealer and remove the No. 2 oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surfaces of the oil pans.

8. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 4 bolts, 2 nuts and baffle plate.
9. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

a. Remove the 18 bolts, 2 nuts and oil pan.

b. Using a screwdriver, remove the oil pan by prying the areas between the cylinder block and oil pan shown in the illustration.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

10. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the 2 bolts, 2 nuts, oil strainer and gasket.
11. REMOVE OIL PUMP ASSEMBLY

a. Remove the 8 bolts.

HINT: Use a 6 mm hexagon wrench for the hexagon head bolt.

b. Using a screwdriver, remove the oil pump by prying the areas between the oil pump and cylinder block shown in the illustration.

NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pump.

c. Remove the O-ring from the cylinder block.

DISASSEMBLY

1. REMOVE OIL PUMP RELIEF VALVE
a. Remove the plug, compression spring and relief valve.

2. REMOVE OIL PUMP ROTOR SET
a. Remove the 10 screws, pump body cover and the drive and driven rotors.

INSTALLATION
1. INSTALL OIL PUMP ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
1 Using a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
2 Thoroughly clean all components to remove all the loose material.
3 Using a non-residue solvent, clean both sealing surfaces.

b. Apply seal packing to the oil pump as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Standard seal diameter: 3 to 4 mm (0.12 to 0.16 inch)

NOTICE:
^ Wipe off any oil from the contact surface.
^ Install the oil pump within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least an hour after installing it.

c. Apply engine oil to a new O-ring.

d. Install the O-ring to the cylinder block.
e. Align the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump onto the crankshaft.

Standard Bolt Length:

f. Install the oil pump with the 8 bolts. Uniformly tighten the bolts in several passes.
Torque: 15.5 Nm (158 kgf-cm, 11 ft. lbs.) for bolt A, B, C and E
30.5 Nm (311 kgf-cm, 22 ft. lbs.) for bolt D

HINT:
^ Use a 6 mm hexagon wrench for the hexagon head bolt.
^ Each bolt length is as shown in the table.

2. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

HINT: The bolt length is 12 mm (0.47 inch).

3. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylinder block, oil pump and rear oil seal retainer.
1 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
2 Thoroughly clean all components to remove all the loose material.
3 Using a non-residue solvent, clean both sealing surfaces.

b. Apply the seal packing to the No. 1 oil pan as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Seal diameter: 3 to 5 mm (0.12 to 0.20 inch)

NOTICE:
^ Wipe off any oil from the contact surface.
^ Install the oil pump within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least an hour after installing it.

Bolt Length:

c. Temporarily install the No. 1 oil pan with the 18 bolts, stud bolt and 2 nuts.

HINT: Each bolt length is as shown in the table.

d. Set the No. 1 oil pan as shown in the illustration.

NOTICE: Make sure the clearance between the rear end of the No. 1 oil pan and cylinder block is 0.2 mm (0.008 inch) or less. If the clearance is more than 0.2 mm (0.008 inch), the No. 1 oil pan will deform when tightening the bolts and nuts.

e. Uniformly tighten the bolts and nuts in several passes.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt A, D
28 Nm (286 kgf-cm, 21 ft. lbs.) for bolt B, C
28 Nm (286 kgf-cm, 21 ft. lbs.) for nut

4. INSTALL OIL PAN BAFFLE PLATE
a. Install the baffle plate with the 4 bolts and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 and No. 2 oil pans.
1 Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
2 Thoroughly clean all components to remove all the loose material.
3 Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the No. 2 oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Seal diameter: 3 to 5 mm (0.12 to 0.20 inch)

NOTICE:
^ Wipe off any oil from the contact surface.
^ Install the oil pan within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least an hour after installing it.

c. Install the No. 2 oil pan with the 20 bolts and 2 nuts.
Uniformly tighten the bolts and nuts in several passes.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

HINT: The bolt length is 14 mm (0.55 inch).

6. INSTALL CRANKSHAFT POSITION SENSOR
7. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install a new gasket to the oil filter bracket.
b. Install the compressor stay, oil cooler and oil filter bracket assembly with the 2 bolts and nut.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
c. Connect the oil cooler hose to the oil cooler.
d. Connect the oil pressure switch connector.

8. INSTALL OIL DIPSTICK GUIDE
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Push the dipstick guide end into the guide hole of the No. 1 oil pan.
d. Install the dipstick guide with the bolt.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
e. Install the dipstick.
9. INSTALL CRANKSHAFT TIMING PULLEY
10. INSTALL TIMING BELT
a. Install the timing belt.
11. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
a. Install the engine and transmission.