Oil Pump: Service and Repair

REMOVAL

HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned.

1. DRAIN ENGINE OIL
2. REMOVE RH FRONT WHEEL
3. REMOVE RH FENDER APRON SEAL
4. REMOVE FRONT EXHAUST PIPE
5. REMOVE GENERATOR FROM ENGINE
6. REMOVE A/C COMPRESSOR FROM ENGINE





7. REMOVE PS PUMP DRIVE BELT AND ADJUSTING STRUT
a. Loosen the pivot and adjusting bolts, and remove the drive belt
b. Remove the bolt, nut and adjusting strut.
8. REMOVE TIMING BELT
9. REMOVE TIMING PULLEYS
10. REMOVE NO.3 TIMING BELT COVER





11. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 2 bolts and housing bracket





12. REMOVE OIL LEVEL SENSOR
a. Disconnect the level sensor connector.
b. Remove the 2 bolts and nut, and disconnect the engine wire.
c. Remove the 4 bolts and oil level sensor.
d. Remove the gasket from the level sensor.

NOTICE: Be careful not to drop the oil level sensor when removing it.

13. REMOVE NO.2 OIL PAN





a. Remove the 10 bolts and 2 nuts.





b. Insert the blade of SST between the No.1 and No.2 oil pans, and cut off applied sealer and remove the No.1 oil pan.
SST 09032-00100

NOTICE:
- Be careful not to the damage the No.2 oil pan contact surface of the No.1 oil pan.
- Be careful not to damage the No.2 oil pan flange.





14. REMOVE OIL STRAINER
Remove the bolt, 2 nuts, oil strainer and gasket.
15. REMOVE NO.1 OIL PAN





a. Remove the 2 bolts and No.1 exhaust pipe support bracket.
b. Remove the 17 bolts and 2 nuts.





c. Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan.

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

16. REMOVE BAFFLE PLATE FROM NO.1 OIL PAN
17. REMOVE CRANKSHAFT POSITION SENSOR





18. REMOVE OIL PUMP
a. Remove the 9 bolts.
b. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap.
c. Remove the O-ring.

DISASSEMBLY





1. REMOVE RELIEF VALVE
Remove the plug, spring and relief valve.





2. REMOVE DRIVE AND DRIVEN ROTORS
Remove the 10 screws, pump body cover, drive and driven rotors.

INSPECTION





1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight.
If it does not, replace the relief valve. If necessary, replace the oil pump assembly.





2. PLACE DRIVE AND DRIVEN ROTORS INTO OIL PUMP BODY
Place the drive and driven rotors into the oil pump body with the mark facing upward.





3. INSPECT ROTOR SIDE CLEARANCE
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
Standard side clearance: 0.030 - 0.090 mm (0.0012 - 0.0035 inch)
Maximum side clearance: 0.15 mm (0.0059 inch)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.





4. INSPECT ROTOR TIP CLEARANCE
Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance: 0.110 - 0.240 mm (0.0043 - 0.0094 inch)
Maximum tip clearance: 0.35 mm (0.0138 inch)
If the tip clearance is greater than maximum, replace the rotors as a set.





5. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driven rotor and body.
Standard body clearance: 0.250 - 0.325 mm (0.0098 - 0.0128 inch)
Maximum body clearance: 0.40 mm (0.0157 inch)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL

HINT: There are 2 methods ((a) and (b)) to replace the oil seal which are as follows:

a. If the oil pump is removed from the cylinder block.





1. Using a screwdriver, pry out the oil seal.





2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010
3. Apply MP grease to the oil seal lip.
b. If the oil pump is installed to the cylinder block.





1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tape the screw driver tip.





3. Apply MP grease to a new oil seal lip.
4. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

REASSEMBLY





1. INSTALL DRIVE AND DRIVEN ROTORS
a. Place the drive and driven rotors into pump body with the marks facing the pump body cover side.
b. Install the pump body cover with the 10 screws.
2. INSTALL RELIEF VALVE
Insert the relief valve and spring into the pump body hole, and install the plug.
Torque: 49.1 Nm (500 kgf-cm, 36 ft. lbs.)

INSTALLATION
1. INSTALL OIL PUMP
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.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a nonresidue solvent, clean both sealing surfaces.





b. Apply seal packing to the oil pump.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





c. Place a new O-ring on the cylinder block.





d. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head: 8 Nm (80 kgf-cm, 69 inch lbs.)
12 mm head: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
2. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
3. INSTALL BAFFLE PLATE TO NO.1 OIL PAN
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
4. INSTALL NO.1 OIL PAN
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a nonresidue solvent, clean both sealing surfaces.





b. Apply seal packing to the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
Region "X" is at the outer side of the bolt hole.
Region "Y" is at the inner side of the bolt hole.
- Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.

c. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque:
10 mm head: 8 Nm (80 kgf-cm, 69 inch lbs.)
12 mm head: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
14 mm head: 37.2 Nm (380 kgf-cm, 27 ft. lbs.)
d. install the No.1 exhaust pipe support bracket with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
5. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
6. INSTALL NO.2 OIL PAN
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 and No.2 oil pans.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a nonresidue solvent, clean both sealing surfaces.

NOTICE: Do not use a solvent which will affect the painted surfaces.





b. Apply seal packing to the No.2 oil pan.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
c. Install the No.2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)





7. INSTALL OIL LEVEL SENSOR
a. Install a new gasket to the level sensor.
b. Install the level sensor with the 4 bolts.
Torque: 8 Nm (80 kgf-cm, 69 inch lbs.)
c. Connect the engine wire with the 2 bolts and nut.
d. Connect the level sensor connector.
8. INSTALL A/C COMPRESSOR HOUSING BRACKET
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
9. INSTALL NO.3 TIMING BELT COVER
10. INSTALL TIMING PULLEYS
11. INSTALL TIMING BELT
12. INSTALL ADJUSTING STRUT AND PS PUMP DRIVE BELT
a. Temporarily install the adjusting strut with the bolt and nut.
b. Install the drive belt with the pivot and adjusting bolts.
Torque: 43.1 Nm (440 kgf-cm, 32 ft. lbs.)
c. Tighten the nut.
Torque: 43.1 Nm (440 kgf-cm, 32 ft. lbs.)
13. INSTALL A/C COMPRESSOR
14. INSTALL GENERATOR
15. INSTALL RH FENDER APRON SEAL
16. INSTALL FRONT EXHAUST PIPE
17. INSTALL RH FRONT WHEEL
18. FILL ENGINE WITH OIL
19. START ENGINE AND CHECK FOR LEAKS
20. RECHECK ENGINE OIL LEVEL