Oil Pump: Service and Repair

LUBRICATION SYSTEM

Components:

INSPECTION

SELECTION OF ENGINE OIL
Recommended API classification: Above SJ or SL
Recommended SAE viscosity grades: 5W-20

NOTE
For best performance and maximum protection of all types of operation, select only those lubricants which

^ Satisfy the requirement of the API classification.
^ Have proper SAE grade number for expected ambient temperature range.

Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.

INSPECTION
1. Check engine oil quality.

Check the oil for deterioration, entry of water, discoloring or thinning.

If the quality is visibly poor, replace oil.

2. Check the engine oil level.

After warning up the engine, make the engine stand still for five minutes or more. The oil level should be between the 'L' and 'F' marks on the dipstick, then. If low, check for leakage and add oil up to the "F" mark.

NOTE
Do not fill with engine oil above the "F" mark.

REMOVAL

OIL PUMP CASE
1. Drain engine oil.
2. Remove the front right wheel and tire.
3. Remove the front right side cover.
4. Remove the front muffler.
5. Remove the generator.
6. Remove the timing belt.
7. Remove the oil filter bracket(A).

8. Using SST(09215-3C000), remove the lower oil pan (A).

CAUTION
Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.

CAUTION
^ Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
^ After tapping the SST with a plastic hammer along the direction of 2 arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
^ Do not turn over the SST abruptly without tapping. It be result in damage of the SST.

9. Remove the oil screen(A).

10. Remove the upper oil pan, using the SST(09215- 3C000)(A).

12. After removing the plug(A), remove the relief spring(B) and the relief plunger(C).

INSPECTION

RELIEF SPRING
1. Check the relief plunger.

Apply engine oil on the plunger and check that it moves smoothly in the hole. If it does not, replace the plunger or the front case only in necessary cases.

2. Check the relief valve spring.

Check deformation or damage of the relief valve spring.

Specification
Free length: 43.8mm(1.7244in.)
Load: 36.3N(3.7kg, 8.2lb)±3.9N(0.4kg, 0.9lb) / 40.1mm(1.5787in.)

OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.

If there is no continuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body when its hole is pushed by a fine rod(A). If there is continuity with pressed, replace the switch.

3. If there is no continuity when the pressure 49.3kpa (0.5kg/cm2, 7.11psi) is applied through the oil hole, the switch is operating properly.

Check for air leakage. If air leaks, the diaphragm is broken. Replace the switch.

REPLACEMENT

OIL AND FILTER

CAUTION
^ Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
^ Wear protective clothing and gloves in order to minimize the length and frequency of contact of your skin to used oil. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
^ In order to preserve environment, used oil or used oil filter must be disposed only at designated disposal sites.

1. Park the car on a level ground.

Start the engine and let it warm up.

2. Turn the engine off.
3. Drain engine oil.
1) Remove the oil filler cap.
2) After lifting the car, remove the oil drain plug(A) and drain oil into a container.
4. Replace the oil filter.
1) Remove the oil filter(B).

2) Check the part number of a new oil filter is as the same as that of the old one.
3) Clean the oil filter bracket surface before installing the new oil filter.
4) Apply engine oil to new oil filter gasket surface.
5) Replace the oil filter.
6) Tighten it slightly until the O-ring of the filter cap contacting on its position.
7) Tighten it with the specified torque.

Tightening torque
11.8 - 15.7Nm(1.2 1.6kgf.m, 8.7 - 11.6lb-ft)

5. Refill with engine oil.
1) Install the oil drain plug with a new gasket.

Tightening torque
34.3 - 44.1Nm (3.5 - 4.5kgf.m, 25.3 - 32.5lb-ft)

2) Fill with fresh engine oil, after removing the engine oil level gauge.

Capacity
Total: 4.5L(4.76U.S.qts,3.96Imp.qts)
Oil pan: 4.2L(4.44U.S.qts,3.70Imp.qts)
Oil filter: 0.3L(0.32U.S.qts,0.26Imp.qts)

3) Install the oil filler cap and the oil level gauge.
6. Start the engine and ensure that no oil is leaking from the drain plug or the oil filter.
7. Recheck engine oil level.

INSTALLATION

OIL PUMP CASE
1. Assembly the relief spring(B) and the relief plunger(C) and tighten the plug(A).

2. Install oil pump case.
1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.

The part must be assembled within 5 minutes after the sealant was applied.

CAUTION
^ Make clean the sealing face before assembling two parts.
^ Remove harmful foreign materials on the sealing face before applying sealant.
^ When applying sealant gasket, sealant must not be protrude into the inside of oil pan.
^ To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
^ After assembly, wait at least 30 minutes before filling the engine with oil.

3) Install the oil pump case(A).

CAUTION
In the installation of the oil pump, always use a new O-ring(B).

3. Using the SST(09214-33000), install the oil pump case oil seal.

4. Install the upper oil pan.
1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.

The part must be assembled within 5 minutes after the sealant was applied.

CAUTION
^ Clean the sealing face before assembling two parts.
^ Remove harmful foreign materials on the sealing face before applying sealant.
^ When applying sealant gasket, sealant must not be protrude into the inside of oil pan.
^ To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
^ After assembly, wait at least 30 minutes before filling the engine with oil.

3) Fix the oil pan and tighten the bolts in several steps uniformly.

5. Install the oil screen(A).

NOTE
Always use a new gasket.

6. Install the lower oil pan.
1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.

The part must be assembled within 5 minutes after the sealant was applied.

7. Install the oil filter bracket(A).

CAUTION
Always use a new O-ring.

8. Install the timing belt, the generator and the front muffler.
9. Install the front right side cover and the wheel and tire.
10. Fill with engine coolant.
11. Start engine and check for leaks.
12. Recheck engine coolant level.