Oil Pump: Service and Repair

REMOVAL

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

1. REMOVE CRANKSHAFT TIMING PULLEY
2. 4WD: REMOVE FRONT DIFFERENTIAL
3. DRAIN ENGINE OIL
4. REMOVE OIL COOLER TUBE AND CLAMP
5. REMOVE REAR END COVER AND DUST COVER
6. DISCONNECT STARTER WIRE CLAMP
7. REMOVE CRANKSHAFT POSITION SENSOR
8. REMOVE OIL PAN





a. Remove the 17 bolts and 2 nuts.





b. Using SST and a brass bar, separate the oil pan from the cylinder block.
SST 09032-00100

HINT: When removing the oil pan, be careful not to damage the oil pan flange.





9. REMOVE OIL STRAINER
Remove the 2 bolt, 2 nuts and oil strainer and gasket.
10. REMOVE OIL PAN BAFFLE PLATE
Remove the bolt, 2 nuts baffle plate.





11. REMOVE OIL PUMP
a. Remove the 8 bolts, ground strap and oil pump.
b. Using a plastic-faced hammer, carefully tap out the oil pump body.
c. Remove the O-ring from the cylinder block.

DISASSEMBLY
1. REMOVE DRIVEN AND DRIVE ROTORS





a. Remove the 8 screws and pump body cover.
Torque: 10 Nm (105 kgf-cm, 8 ft. lbs.)





b. Remove the drive and driven rotors.

HINT: At the time of reassembly, please refer to the following items. Place the drive and driven rotor into pump body with the marks facing the pump body cover side.





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

INSPECTION





1. INSPECT RELIEF VALVE
Coat the relief valve with engine oil and check that it falls smoothly into the valve hole by its own weight.
If the valve does not fall smoothly, replace the valve and/or oil pump assembly.
2. INSPECT DRIVE AND DRIVEN ROTORS





a. Inspect the rotor for body clearance.
Using a feeler gauge, measure the clearance between the driven rotor and pump body.
Standard clearance: 0.10 - 0.18 mm (0.0039 - 0.0069 inch)
Maximum clearance: 0.30 mm (0.0118 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set and/or pump body.





b. Inspect the rotors for tip clearance.
Using a feeler gauge, measure the clearance between the drive and driven rotors.
Standard clearance: 0.11 - 0.24 mm (0.0043 - 0.0094 inch)
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set.





c. Inspect the rotors for side clearance.
Using a feeler gauge and precision straight edge, measure the side clearance between the rotors and precision straight edge.
Standard clearance: 0.03 - 0.09 mm (0.0012 - 0.0035 inch)
Maximum clearance: 0.15 mm (0.0059 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set and/or pump body.

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL

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

a. If oil pump is removed from 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 09309-37010
3. Apply MP grease to the oil seal lip.
b. If 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 screwdriver 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 09306-37010

REASSEMBLY
Reassembly is in the reverse order of disassembly.

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 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
- Install nozzle that has been cut out 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 5 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 into the groove of the cylinder block.





d. Install the oil pump to the crankshaft with the spline teeth of the drive rotor engaged with the large teeth of the crankshaft.





e. Install the oil pump and ground strap with the 8 bolts.
Torque:
Bolt A: 20 Nm (200 kgf-cm, 15 ft. lbs.)
Bolt B: 42 Nm (420 kgf-cm, 31 ft. lbs.)
2. INSTALL CRANKSHAFT POSITION SENSOR
3. INSTALL OIL PAN BAFFLE PLATE
Install the baffle plate with the bolt and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
4. INSTALL OIL STRAINER
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.)
5. INSTALL OIL PAN
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the, oil pan, cylinder block and sealing grooves.
1. Using a razor blade and gasket scraper, remove all the remaining seal packing (FIPG) material from the gasket surfaces.
2. Thoroughly clean all components to remove all the loose material.
3. Clean both sealing surfaces with a non-residue solvent.

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





b. Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
1. Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.

HINT: Avoid applying an excess amount to the surface.

2. If parts are not assembled within 5 minutes of applying the seal packing, the effectiveness of the seal packing is lost and the seal packing must be removed and reapplied.
3. Immediately remove the nozzle from the tube and reinstall the cap after using the seal packing.
c. Install the oil pan with the 4 nuts and 15 bolts.
Torque: 7.6 Nm (78 kgf-cm, 67 inch lbs.)
6. INSTALL FLYWHEEL HOUSING UNDER, COVER DUST AND STIFFENER PLATE
7. CONNECT STARTER WIRE CLAMP
8. A/T: INSTALL OIL COOLER TUBE AND CLAMP
9. INSTALL CRANKSHAFT TIMING PULLEY
10. 4WD: INSTALL FRONT DIFFERENTIAL
11. FILL WITH ENGINE OIL
12. START ENGINE AND CHECK FOR LEAKS
13. INSTALL ENGINE UNDER COVER
14. RECHECK ENGINE OIL LEVEL