Oil Pump Assembly Replacement

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. A/T:
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 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.


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.
- Using a razor blade and gasket scraper, remove all the remaining seal packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- 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
- 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.

- 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.
- 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