Oil Pump: Service and Repair

REMOVAL

HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned.

1. REMOVE HOOD
2. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE OIL
5. REMOVE SUSPENSION LOWER CROSSMEMBER
6. REMOVE FRONT EXHAUST PIPE
7. REMOVE ENGINE MOUNTING CENTER MEMBER
8. REMOVE FRONT ENGINE MOUNTING INSULATOR AND BRACKET
9. REMOVE STIFFENER PLATE

Remove the two bolts and stiffener plate.

10. REMOVE OIL PAN

(a) Remove the dipstick.
(b) Remove the fifteen bolts and four nuts.

(c) Insert the blade of SST between the cylinder block and oil pan, cut off applied sealer and remove the oil pan.

NOTICE:
- Do not use SST for the oil pump body side and rear oil seal retainer.
- Be careful not to damage the oil pan flange.

11. REMOVE OIL PAN BAFFLE PLATE

Insert the blade of SST between the cylinder block and baffle plate, cut off applied sealer and remove the baffle plate.

NOTICE:
- Do not use SST for the oil pump body side and rear oil seal retainer.
- Be careful not to damage the baffle plate flange.

12. REMOVE OIL STRAINER

Remove the bolt, two nuts, oil strainer and gasket.

13. SUSPEND ENGINE WITH ENGINE HOIST CHAIN

14. REMOVE TIMING BELT, NO.1 IDLER AND CRANKSHAFT TIMING PULLEYS

15. (w A/C) REMOVE ALTERNATOR

16. (w A/C) REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES

17. (w A/C) REMOVE A/C COMPRESSOR BRACKET
18. REMOVE PS BELT ADJUSTING BAR
19. REMOVE OIL PUMP

(a) Remove the nine bolts.
(b) Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap.
(c) Remove the 0-ring.

DISASSEMBLY

1. REMOVE RELIEF VALVE

(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retainer, spring and relief valve.

2. REMOVE DRIVE AND DRIVEN ROTORS

Remove the eight 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 does not, replace the relief valve. If necessary, replace the oil pump assembly.

2. INSPECT DRIVE AND DRIVEN ROTORS

A. 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 in.)

Maximum body clearance:
0.30 mm (0.0118 in.)

If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

B. 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 in.)

Maximum side clearance:
0.15 mm (0.0059 in.)

If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

C. Inspect rotor tip clearance

Using a feeler gauge, measure the clearance between the drive and driven rotors.

Standard tip clearance:
0.110 - 0.240 mm
(0.0043 - 0.0094 in.)

Maximum tip clearance: 0.35 mm (0.0138 in.)

If the tip clearance is greater than maximum, replace the rotors as a set.

ASSEMBLY

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 eight screws.

2. INSTALL RELIEF VALVE

(a) Insert the relief valve, spring and retainer into the pump body hole.
(b) Using snap ring pliers, install the snap ring.

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 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.

- Install a nozzle that has been cut to a 2-3 mm (0.08-0.12 in.) of 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.

(d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide.

(e) Install the oil pump with the nine bolts.

Torque:
12 mm head bolt (C and D)
200 kg-cm (14 ft-lb, 20 Nm)

14 mm head bolt (A and B)
420 kg-cm (30 ft-lb, 41 Nm)

2. INSTALL PS BELT ADJUSTING BAR
3. (w A/C) INSTALL A/C COMPRESSOR BRACKET
4. (w A/C) INSTALL ALTERNATOR
5. (w/ A/C) INSTALL A/C COMPRESSOR BRACKET
6. INSTALL CRANKSHAFT TIMING PULLEY, NO.1 IDLER PULLEY AND TIMING BELT
7. REMOVE ENGINE HOIST CHAIN FROM ENGINE
8. INSTALL OIL PAN BAFFLE PLATE

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the baffle plate and cylinder block.

- Using a razor blade and gasket scraper. remove all the old packing (FIPG) material from the gasket surfaces.
- 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 baffle plate as shown in the illustration.

- Install a nozzle that has been cut to a 3-4 mm (0.12-0.16 in.) of 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) Install the baffle plate.

9. INSTALL OIL STRAINER

Install a new gasket and the oil strainer with the bolt and two nuts.

Torque: 70 kg-cm (61 in. lb, 6.9 Nm)

10. INSTALL 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 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.

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.

- Install a nozzle that has been cut to 3-4 mm (0.12 - 0.16 in.) of opening.

HINT: Avoid applying an excessive amount to the surface. Be particularly careful near oil passages.

- 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 oil pan with the fifteen bolts and four nuts.

Torque: 60 kg-cm (52 in. lb, 5.9 Nm)

(d) Install the dipstick.

10. INSTALL STIFFENER PLATE

Install the stiffener plate with the two bolts.

Torque: 380 kg-cm (27 ft-lb, 37 Nm)

11. INSTALL FRONT ENGINE MOUNTING BRACKET AND INSULATOR
12. INSTALL ENGINE MOUNTING CENTER MEMBER
13. REMOVE FRONT EXHAUST PIPE
14. INSTALL SUSPENSION LOWER CROSSMEMBER
15. INSTALL ENGINE UNDER COVERS
16. LOWER VEHICLE
17. FILL WITH ENGINE OIL
18. START ENGINE AND CHECK FOR LEAKS
19. RECHECK ENGINE OIL LEVEL
20. INSTALL HOOD