Oil Pump: Service and Repair

FRONT CASE, OIL PUMP





DISASSEMBLY





1. Remove the timing belt. Refer to "Timing Belt."
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen.
5. Remove the front case assembly.
6. Remove the oil pump cover.
7. Remove the inner and outer gears from the front case. The mating marks on the inner and outer gears indicate the direction of installation. Make sure that the inner and outer gears are installed as shown.
8. Remove the plug and remove the relief spring and relief plunger.

INSPECTION

Front Case
1. Check the front case for cracks or damage. Replace as necessary.
2. Check the front oil seal for worn or damaged lips. Replace if defective.

Oil Pan and Oil Screen
1. Check the oil pan for failure, damage or cracks. Replace if defective.
2. Check the oil screen for failure, damage and cracks and replace if defective.

Front Case and Oil Pump Cover
Worn (especially stepped) or damaged surfaces contacting gears.

OIL PUMP GEARS





1. Worn or damaged gear tooth surfaces.
2. Clearance between outer gear and front case.

Outer gear:
Clearance between outer circumference and front case: 0.12 - 0.185mm (0.005 - 0.007 inch)





3. Check the tip clearance on the pump rater.

Standard value: 0.025 - 0.069 mm (0.001 - 0.003 inch)





4. Check the axial clearance on the outer pump rater.

Standard value: 0.06 - 0.11 mm (0.0024 - 0.0043 inch)





5. Check the axial clearance on the inner pump rater.

Standard value: 0.04 - 0.085 mm (0.0016 - 0.0033 inch)

Relief Valve and Spring
1. Check sliding condition of the relief valve inserted in the front case.
2. Inspect for distorted or broken relief valve spring.

Free height: 43.8 mm (1.724 inch)
Load: 3.7 kg/40.1 mm (8.14 lb/1.579 inch)

REASSEMBLY

Oil Pump





1. Install the outer and inner gears into the front case. Make sure that the inner and outer gears are installed in the same direction as shown.
2. Install the oil pump cover and tighten the bolts to the specified torque. After the bolts have been tightened, check to ensure that the gear turns smoothly.

Oil pump cover bolt: 6 - 9 Nm (60 - 90 kg.cm, 4 - 6.6 ft. lbs.)

3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.

Relief valve plug: 40 - 50 Nm (400 - 500 kg.cm, 29 - 36 ft. lbs.)

Front Case





Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.

Body length:
(A): 25 mm (0.98 inch) 20 mm
(B): (0.787 inch)
(C): 38 mm (1.496 inch)
(D): 45 mm (1.771 inch)


20 - 27 Nm (200 - 270 kg.cm, 14.5 - 19.8 ft. lbs.)

OIL SEAL





1. Inspect for worn, distorted spring lips.
2. Check for elongated spring ring.
3. Always use a new oil seal when reassembling.





4. Use Special Tool, Mounting Bushing Remover and installer Arbor (09216-21000), install the oil seal.
5. Install the crankshaft sprocket, timing belt and crankshaft pulley. Refer to "Timing Belt".
6. Install the oil screen.
7. Clean both gasket surfaces of the oil pan and the cylinder block.





8. Apply sealant into the groove of the oil pan flange as shown.

CAUTION:
1) Apply sealant approx. 4 mm (0.16 inch) in thickness.
2) After application of sealant, do not exceed 15 minutes before installing the oil pan.

9. Install the oil pan and tighten the bolts to the specified torque.

Oil pan bolt: 6 - 8 Nm (60 - 80 kg.cm, 4 - 6 ft. lbs.)