Oil Pump Overhaul

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. 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 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.





4. INSPECT ROTOR 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: 0.15 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.





5. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driven rotor and body.

Standard body clearance: 0.100 - 0.175 mm (0.0039 - 0.0069 inch)
Maximum body clearance: 0.30 mm (0.0118 inch)

If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.
6. REMOVE DRIVE AND DRIVEN 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 oil pump body cover with the 10 screws.

Torque: 10 Nm (7 ft. lbs.)





2. INSTALL RELIEF VALVE
a. Insert these parts into the oil pump body hole:
- Relief valve
- Compression spring
b. Install the plug.

Torque: 49 Nm (36 ft. lbs.)


INSTALLATION





1. INSTALL OIL PUMP
a. Remove any old packing Formed In Place Gasket (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:
12 mm head: 15.5 Nm (11 ft. lbs.)
14 mm and 6 mm hexagon socket head: 30.5 Nm (22 ft. lbs.)

HINT:
- Use a 6 mm hexagon wrench for the hexagon socket 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
40 mm (1.57 inch) for D of 14 mm head
30 mm (1.18 inch) for E of 6 mm hexagon socket head





2. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.

Torque: 6.5 Nm (58 inch lbs.)

b. Connect the crankshaft position sensor connector.





3. INSTALL OIL FILTER AND FILTER BRACKET ASSEMBLY
a. Install a new gasket to the oil filter bracket.





b. Install the oil filter and filter bracket assembly with the stud bolt, bolt and nut.

Torque: 18 Nm (13 ft. lbs.)

c. Connect the oil pressure switch connector.





4. INSTALL OIL STRAINER
Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

Torque: 7.5 Nm (66 inch lbs.)

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

5. 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 No.1 oil pan as shown in the illustration.

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.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and rein stall cap.





c. Temporarily install the No.1 oil pan with the 16 bolts and 2 nuts.

HINT: Each bolt length is indicated in the illustration.

Bolt length:
20 mm (0.78 inch) for A of 10 mm head
25 mm (0.98 inch) for B of 12 mm head
55 mm (2.17 inch) for C of 12 mm head
35 mm (1.38 inch) for D of 10 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 and nuts in several passes.

Torque:
Bolt:
7.5 Nm (66 inch lbs.) for 10 mm head
28 Nm (21 ft. lbs.) for 12 mm head
Nut: 28 Nm (21 ft. lbs.)





6. INSTALL OIL PAN BAFFLE PLATE
Install the baffle plate with the 6 bolts and 2 nuts.

Torque: 7.5 Nm (66 inch lbs.)

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

7. 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 - 4 mm (0.12 - 0.16 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 12 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:
Bolt: 7.5 Nm (66 inch lbs.)
Nut: 28 Nm (21 ft. lbs.)

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





8. INSTALL OIL LEVEL SENSOR
a. Install a new gasket to the level sensor.





b. Install the level sensor with the 4 bolts.

Torque: 5.4 Nm (48 inch lbs.)

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

c. Connect the level sensor connector.
9. INSTALL BRACKET OF HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) CONNECTOR TO NO.1 OIL PAN
Connect the connector bracket with the bolt.
10. 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.
11. INSTALL CRANKSHAFT TIMING PULLEY
12. INSTALL NO.1 AND NO.2 IDLER PULLEYS
13. INSTALL TIMING BELT
14. DISCONNECT ENGINE FROM ENGINE STAND
15. REASSEMBLE ENGINE AND TRANSMISSION
16. INSTALL ENGINE TO BODY