Oil Pump: Service and Repair

Oil Pump

Non-turbo model:

REMOVAL
1. Disconnect the ground cable from battery.

2. Remove the collector cover. (Turbo model)
3. Lift-up the vehicle.
4. Remove the under cover.
5. Remove the bolts which install water pipe of oil cooler to oil pump.
6. Remove the water pipe and hoses between oil cooler and water pump.

^ Non-turbo AT model

^ Turbo model

7. Remove the radiator.
8. Remove the crankshaft position sensor.

9. Remove the V-belts. (Non-turbo model)
10. Remove the back side V-belt tensioner.

11. Remove the crank pulley using ST.
ST 499977100 CRANK PULLEY WRENCH

12. Remove the water pump.
13. Remove the timing belt guide. (MT model)

14. Remove the crank sprocket.

15. Remove the bolts which install oil pump onto cylinder block.

NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.

16. Remove the oil pump by using flat tip screwdriver.

CAUTION: Be careful not to scratch mating surfaces of cylinder block and oil pump.

INSTALLATION
Install in the reverse order of removal. Perform the following.
1. Apply liquid gasket to the mating surfaces of oil pump.
Liquid gasket. Three bond 1215 (Part No. 004403007) or equivalent

2. Replace O-ring (A) with a new one.
3. Apply a coat of engine oil to the inside of oil seal.

4. Position the oil pump, aligning the notched area with crankshaft, and push the oil pump straight.

CAUTION:
^ Make sure the oil seal lip is not folded.
^ Be careful not to scratch the oil seal when installing oil pump on cylinder block.

5. Install the oil pump.
6. Apply liquid gasket to the three bolts thread. (if the bolts are reused)
Liquid gasket. Three bond 1324 (Part No.004403042) or equivalent
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)

DISASSEMBLY
Remove the screw which secures oil pump cover and then disassemble oil pump. Inscribe alignment marks on the inner and outer rotors so that they can be replaced in their original positions during reassembly.

CAUTION: Before disassembling the oil pump, remove the relief valve.

ASSEMBLY
1. Assemble the front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER

NOTE: Use a new oil seal.

2. Apply a coat of engine oil to inner and outer rotors.
3. Assemble the inner and outer rotors in their original positions.
4. Assemble the oil relief valve and install relief valve spring and plug.

NOTE: Use a new gasket.

5. Assemble the oil pump cover.
Tightening torque:
T1: 5.4 Nm (0.55 kgf-m, 4.0 ft. lbs.)
T2: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.)

INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance exceeds the limit, replace rotors as a matched set.
Tip clearance:
Specification: 0.04 - 0.14 mm (0.0016 - 0.0055 inch)
Service limit. 0.18 mm (0.0071 inch)

2. CASE CLEARANCE
Measure the clearance between outer rotor and oil pump case. If the clearance exceeds the limit, replace the rotor.
Case clearance:
Specification: 0.10 - 0.175 mm (0.0039 - 0.0069 inch)
Service limit. 0.20 mm (0.0079 inch)

3. SIDE CLEARANCE
Measure the clearance between oil pump inner rotor and oil pump cover. If the clearance exceeds the limit, replace rotor or oil pump case.
Side clearance:
Specification: 0.02 - 0.07 mm (0.0008 - 0.0028 inch)
Service limit: 0. 12 mm (0.0047 inch)

4. OIL RELIEF VALVE
Check the valve for assembly condition and damage, and the relief valve spring for damage and deterioration. Replace the parts if defective. Relief valve spring
Free length: 73.7 mm (2.902 inch)
Installed length: 54.7 mm (2.154 inch)
Load when installed. 93.1 N (9.49 kgf, 20.88 lb)

5. OIL PUMP CASE
Check the oil pump case for worn shaft hole, clogged oil passage, worn rotor chamber, cracks and other faults.

6. OIL SEAL
Check the oil seal lips for deformation, hardening, wear, etc. and replace if defective.