Disassembly and Assembly

DISASSEMBLY





1. Remove relief valve.
Remove the plug, gasket, spring and relief valve.





2. Remove drive and driven rotors.
Remove the 9 screws, pump body cover, 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 does not, 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 side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.

Standard side clearance: 0.030 - 0.090 mm (0.0012 - 0.0035 inch)
Maximum side 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.





4. 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.





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.

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 pump body cover with the 9 screws.
2. Install relief valve.
Insert the relief valve and spring into the pump body hole, and install the plug with a new gasket.

Torque: 36.8 Nm (37 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 oil 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 a nozzle that has been cut 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 3 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 on the cylinder block.





d. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft and side the oil pump on the crankshaft.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.

Torque:
10 mm head: 8 Nm (69 inch lbs.)
12 mm head: 19.5 Nm (14 ft. lbs.)

2. Install crankshaft position sensor.
3. Install baffle plate to No.1 oil pan.

Torque: 8 Nm (69 inch lbs.)





4. 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 oil pan, 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
Region "X" is at the outer side of the bolt hole.
Region "Y" is at the inner side of the bolt hole.

- Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.

c. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:
10 mm head: 8 Nm (69 inch lbs.)
12 mm head: 19.5 Nm (14 ft. lbs.)
14 mm head: 37.2 Nm (27 ft. lbs.)

d. Install the flywheel housing under cover and exhaust pipe support stay with the 2 volts.

Torque: 7.8 Nm (69 inch lbs.)

5. Install oil strainer.
Install a new gasket and the oil strainer with the 3 nuts.

Torque: 8 Nm (69 inch lbs.)





6. Install No.2 oil pan.
a. Remove the 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 oil 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.

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 4 - 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 3 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 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque: 8 Nm (69 inch lbs.)

7. Install A/C compressor housing bracket.

Torque: 25 Nm (18 ft. lbs.)

8. Install No.3 timing belt cover.
9. Install timing pulleys.
10. Install timing belt.
11. Install adjusting strut and PS pump drive belt.
a. Temporarily install the adjusting strut with the bolt and nut.
b. Install the drive belt with the pivot and adjusting bolts.

Torque: 43.1 Nm (32 ft. lbs.)

c. Tighten the nut.

Torque: 43.1 Nm (32 ft. lbs.)

12. Install A/C compressor.
13. Install generator drive belt.
14. Install front exhaust pipe bracket to No.1 oil pan.

Torque: 21 Nm (15 ft. lbs.)

15. Install front exhaust pipe.
16. Remove engine under cover.
17. Remove RH fender apron seal.
18. Remove RH front wheel.
19. Fill engine with oil.
20. Start engine and check for leaks.
21. Recheck engine oil level.