Overhaul

Engine Oil Pump Overhaul

Exploded View





NOTE: Refer to the Exploded View if needed during this procedure.

Oil Pump Removal

1. Turn the crankshaft pulley so its top dead center (TDC) mark (A) lines up with the pointer (B).





2. Remove the oil pan Engine Oil Pan Removal.

3. To hold the rear balancer shaft, insert a 6 mm long pin punch (Snap-on PPC108LA or equivalent) (A) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.





4. Turn the crankshaft counterclockwise to compress the oil pump chain auto-tensioner.

5. Align the holes on the lock (A) and the oil pump chain auto-tensioner (B), then insert a 3.0 mm (7/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

NOTE: Check the oil pump chain auto-tensioner cam position. If the position is not aligned, set the first cam to the first edge of the rack.






6. Loosen the oil pump sprocket mounting bolt (A).






7. Remove the oil pump sprocket (A) and the oil pump (B), then remove the oil pump chain auto-tensioner (C).






Oil Pump Inspection

1. Remove the pump housing.






2. Align the inner rotor tooth (A) with the mark (B) on the outer rotor, then check the inner rotor-to-outer rotor radial clearance between the inner rotor and the outer rotor. If the inner rotor-to-outer rotor radial clearance exceeds the service limit, replace the oil pump.










3. Check the pump housing-to-rotor axial clearance between the rotor (A) and the pump housing (B). If the pump housing-to-rotor axial clearance exceeds the service limit, replace the oil pump.










4. Check the pump housing-to-outer rotor radial clearance between the outer rotor (A) and the pump housing (B). If the pump housing-to-outer rotor radial clearance exceeds the service limit, replace the oil pump.










Balancer Shaft Inspection

1. Seat the balancer shaft by pushing it away from the oil pump sprocket end of the oil pump.

2. Zero the dial indicator against the end of the rear balancer shaft, then push the rear balancer shaft back and forth and read the end play.










3. Remove the pump housing.






4. Remove the upper balancer shaft holder (with bearings) (A) and the baffle plates (B), then remove the front balancer shaft (C) and the rear balancer shaft (D).






5. Measure the inner diameter of the No. 1 bearing for the front balancer shaft hole and the rear balancer shaft hole.






Front





Rear





6. Measure the diameters of the No. 1 journals on the front balancer shaft and the rear balancer shaft.






Front





Rear





7. Clean both balancer shaft No. 2 journals and the bearing halves with a clean shop towel, then place both balancer shafts into the balancer holder.

8. Place one strip of plastigage across each No. 2 journal.

9. Reinstall the bearings and the upper balancer shaft holder, then tighten the bolts.

NOTE: Do not rotate the balancer shafts during inspection.






10. Remove the upper balancer shaft holder and the bearings again, and measure the widest part with the plastigage. If balancer shaft No. 2 journal oil clearance is out-of-tolerance, install new bearings, and recheck. If it is still out-of-tolerance, replace the balancer shafts.










11. Align the punch mark on the rear balancer shaft in the center of the two punch marks on the front balancer shaft, then install the balancer shafts on the lower balancer shaft holder.






12. Apply new engine oil to the threads of the 8 mm bolts (A).





13. Install the upper balancer shaft holder (B) with a new O-ring (C).

14. Install the pump housing.






Oil Pump Installation

1. Make sure the No. 1 piston top dead center (TDC) mark (A) lines up with the pointer (B).






2. Align the dowel pin (A) on the rear balancer shaft with the mark (B) on the oil pump.






3. To hold the rear balancer shaft, insert a 6 mm long pin punch (Snap-on PPC108LA or equivalent) (A) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.






4. Turn the plate (A) counterclockwise, to release the lock, then push the oil pump chain auto-tensioner arm (B), and set the first cam (C) to the first edge of the rack (D). Insert a 3.0 mm (7/64 in) diameter pin (E) into the hole (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will become damaged.






5. Install the oil pump chain auto-tensioner (A).





6. Apply new engine oil to the threads of the oil pump mounting bolts (B) and the oil pump sprocket mounting bolt (C), then Loosely install the oil pump (D) with a new O-ring (E), then install the oil pump sprocket (F).

7. Tighten the oil pump mounting bolts and the oil pump sprocket mounting bolt.

8. Remove the 6 mm long pin punch (G).

9. Remove the 3.0 mm (7/64 in) diameter pin (A) from the oil pump chain auto-tensioner.





10. Install the oil pan Engine Oil Pan Installation.