Oil Pump: Service and Repair

REMOVAL

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

1. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE
2. SEPARATE ENGINE AND TRANSMISSION
3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
4. REMOVE TIMING BELT
5. REMOVE NO.1 IDLER PULLEY
6. REMOVE NO.2 IDLER PULLEY
7. REMOVE CRANKSHAFT TIMING PULLEY





8. REMOVE OIL DIPSTICK AND GUIDE
a. Remove the bolt holding the oil dipstick to the LH cylinder head.
b. Pull out the dipstick guide together with the dipstick from the No.1 oil pan.
c. Remove the O-ring from the dipstick guide.
9. REMOVE OIL LEVEL SENSOR
a. Remove the 4 bolts and level sensor.
b. Remove the gasket from the level sensor.
10. REMOVE FILTER BRACKET ASSEMBLY
a. Disconnect the 2 water bypass hoses from the oil cooler.
b. Disconnect the oil pressure switch connector.
c. Remove the stud bolt, 2 nuts, the filter bracket assembly with the oil filter and oil cooler.
d. Remove the gasket from the filter bracket.
11. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the position sensor connector.
b. Remove the bolt and position sensor.
12. REMOVE NO.2 OIL PAN
a. Remove the 13 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 No.2 oil pan contact surface of the No.1 oil pan.
- Be careful not to damage the No.2 oil pan flange.





13. REMOVE OIL PAN BAFFLE PLATE
Remove the 4 bolts, 2 nuts and baffle plate.
14. REMOVE NO.1 OIL PAN





a. Remove the 18 bolts and 2 nuts.





b. Using a screwdriver, remove the No.1 oil pan by prying between the oil pan and cylinder block.
15. REMOVE OIL STRAINER
Remove the 2 bolts, 2 nuts, oil strainer and gasket.
16. REMOVE OIL PUMP





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 portions between the oil pump and cylinder block.
c. Remove the O-ring from the cylinder block.

DISASSEMBLY





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





2. REMOVE DRIVE AND DRIVEN ROTORS
Remove the 10 screws, pump body cover, the 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 doesn't, replace the relief valve. If necessary, replace the oil pump assembly.
2. INSPECT DRIVE AND DRIVEN ROTORS
a. Place the drive and driven rotors into the oil pump body.





b. Inspect the rotors for the body clearance.
Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance: 0.060 - 0.180 mm (0.0024 - 0.0071 inch)
Maximum tip clearance: 0.18 mm (0.0071 inch)
If the tip clearance is greater than maximum, replace the rotors as a set.





c. Inspect the rotors for the side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.
Standard body clearance: 0.030 - 0.090 mm (0.0012 - 0.0035 inch)
Maximum body clearance: 0.09 mm (0.0035 inch)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.





d. Inspect the rotor for the 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: 0.325 mm (0.0128 inch)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.
e. Remove the drive and drive rotors.

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL

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.
Torque: 10 Nm (105 kgf-cm, 7 ft. lbs.)





2. INSTALL RELIEF VALVE
a. Insert the relief valve and compression spring into the oil pump body hole.
b. Install the plug.
Torque: 49 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 groove.
- Thoroughly clean all components to remove all the loose material.
- 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

NOTICE: Avoid applying an excessive amount to the surface. Be particularly careful near oil passage.

- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





c. Install a new O-ring to 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 8 bolts. Uniformly tighten the bolts in several passes.
Torque:
15.5 Nm (160 kgf-cm, 11 ft. lbs.) for 12 mm head and stud bolt (B)
30.5 Nm (310 kgf-cm, 22 ft. lbs.) for 14 mm head and 6 mm hexagon head

NOTICE: Do not reuse the stud bolt (B).

HINT:
- Use a 6 mm hexagon wrench for the hexagon head bolt.
- Each bolt length is indicated in the illustration.
Bolt length:
50 mm (1.97 inch) for A of 12 mm head
106 mm (4.17 inch) for B of 12 mm head
30 mm (1.18 inch) for C of 12 mm head
44 mm (1.73 inch) for D of 14 mm head
28 mm (1.10 inch) for E of 6 mm hexagon head





2. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the 2 bolts and nuts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)

HINT: Use bolt 12 mm (0.47 inch) in length.

3. 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 No.1 oil pan, cylinder block, oil pump and rear oil seal retainer.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the Nod oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.





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

HINT: Each bolt length is indicated in the illustration.
Bolt length:
A: 20 mm (0.79 inch) of 10 mm head
B: 35 mm (1.38 inch) of 10 mm head
C: 60 mm (2.36 inch) of 12 mm head
D: 25 mm (0.98 inch) of 12 mm head

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

NOTICE: Make sure the clearance between the rear ends 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 be stretched.

e. Uniformly tighten the bolts, stud bolts and nuts in several passes.
Torque:
7.5 Nm (80 kgf-cm, 66 inch lbs.) for 10 mm head
28 Nm (290 kgf-cm, 21 ft. lbs.) for 12 mm head





4. INSTALL OIL PAN BAFFLE PLATE
Install the baffle plate with the 4 bolts and 2 nuts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)





5. INSTALL NO.2 OIL PAN
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.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue 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 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 inch) opening.
- Parts must be assembled within 5 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 13 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)

HINT: Use bolts 14 mm (0.55 inch) in length.





6. INSTALL OIL LEVEL SENSOR
a. Install a new gasket to the level sensor as shown in the illustration.
b. Install the level sensor with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

HINT: Use bolts 16 mm (0.63 inch) in length.

7. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the position sensor with the bolt.
Torque: 6.5 Nm (65 kgf-cm, 58 inch lbs.)

HINT: Use bolt 17 mm (0.67 inch) in length.

b. Connect the position sensor connector.
8. INSTALL FILTER BRACKET ASSEMBLY
a. Install the a new gasket to the oil filter bracket.
b. Install the oil filter and filter bracket assembly with the stud bolt and 2 nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c. Connect the oil pressure switch connector.
d. Connect the 2 water bypass hoses to the oil cooler.





9. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Push in the dipstick guide end into the guide hole of the No. 1 oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
10. INSTALL CRANKSHAFT TIMING PULLEY
11. INSTALL NO.1 IDLER PULLEY
12. INSTALL NO.2 IDLER PULLEY
13. INSTALL TIMING BELT
14. DISCONNECT ENGINE FROM ENGINE STAND
15. ASSEMBLE ENGINE AND TRANSMISSION
16. INSTALL ENGINE AND TRANSMISSION ASSEMBLY TO VEHICLE