Oil Pump: Service and Repair

REMOVAL





1. Remove the timing belt.
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.





8. Using the special tool, remove the plug cap from the oil pump portion of front case.





9. Remove the left side cylinder block plug and insert a screwdriver with an 8 mm (0.32 inch) diameter shaft into plug hole. Screwdriver shaft must be inserted more than 60 mm (2.4 inch)





10. Remove the oil pump driven gear and left counter balance shaft retaining bolt.





11. Remove the front case mounting bolts and remove front case assembly and gasket. Remove the two counterbalance shafts from the cylinder block.





12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from front case.

INSPECTION
Front Case
1. Check oil holes for clogging and clean if necessary.
2. Check counter balance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front case.
3. Check the front case for cracks and other damage. Replace cracked or damaged front case.

Counter Balance Shaft





Check journals for wear or seizure.
If excessive wear or seizure is evident, check bearing as well. If necessary, replace counter balance shaft bearing or both.

Oil Seal
1. Check the oil seal lip for wear and damage. Replace oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace oil seal if necessary.

Oil Pressure Switch





1. If "OIL PRESSURE" indicating lamp lights when ignition switch is set to "ON" and goes out when engine is started and runs at idle, then everything is in order. If "OIL PRESSURE" lamp does not light when ignition switch is set to "ON", check switch, lamp and wiring.
2. If there is current flow when ignition switch is set to "ON" and if there is no current flow when engine is running at idle, switch is good.
If switch is good, check lamp and wiring.
Oil pressure switch operation pressure: 14.71-29.42 kPa (0.15-0.3 kg/cm2, 2.1-4.3 psi)





3. Using 24 mm deep socket, tighten the switch to the specified torque.
Tightening torque:
Oil pressure switch and sender assy: 8-12 Nm (80-120 kg.cm, 5.8-8.7 ft. lbs.)

Oil Pressure Sender Assy





1. Check the continuity between the terminal and the body with an ohmmeter.
If there is continuity, replace the oil pressure switch.





2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace it.
3. Or, if there is no continuity when a 50 kPa (7 psi) pressure is applied through the oil hole, the switch is operating properly.
Check to see that air doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.

Oil Pump
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and gear surface of the oil pump cover.





3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears.
Standard value:
Drive gear: 0.16-0.21 mm (0.0063-0.0083 inch)
Driven gear: 0.13-0.18 mm (0.0051-0.0071 inch)
Limit:
Drive gear: 0.245 mm (0.0098 inch)
Driven gear: 0.25 mm (0.0098 inch)





4. Check the side clearance.

COUNTER BALANCE SHAFT BEARING REPLACEMENT





1. Using special tool, remove the right counterbalance shaft front bearing from the cylinder block.





2. Using special tool, remove the right counter balance shaft rear bearing from the cylinder block.





3. Using special tool, remove the left counter balance shaft rear bearing from cylinder block. At this time, install special tool on front surface of cylinder block to hold bearing puller.





4. Using special tool, install the left counter balance shaft rear bearing to the cylinder block.

NOTE:
1. Apply engine oil to the rear bearing outer circumference and bearing hole in cylinder block.
2. The left rear bearing has no oil holes.





5. Using special tool, install the right counter balance shaft rear bearing to the cylinder block.

NOTE:
1. Apply engine oil to outer surface of bearing.
2. Make sure that bearing oil hole is aligned with oil hole of cylinder block.





6. Using special tool, install the right counter balance shaft front bearing to the cylinder block.





NOTE: Make sure that bearing oil hole is aligned with oil hole of cylinder block.

INSTALLATION





1. Apply engine oil to the gear and align the two timing marks.





2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil sea] into the front case.





3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to outer circumference of the special tool to install the front case.





4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).





5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Front case assembly:
Tightening torque:
All Except: 20-27 Nm (200-270 kg.cm, 14-20 ft. lbs.)





6. Insert screwdriver through plug hole in left side of cylinder block to check shaft in position, and then tighten.





7. Install a new O-ring to the groove of front case.
8. Using special tool, install the plug case and tighten to specified torque.





9. Apply sealant into the groove of the pan flange as shown.

NOTE:
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.





10. Note the difference in bolt lengths at the location shown.
Install the oil pan and tighten the bolts to the specified torque.
Tightening torque:
Oil pan bolt: 10-12 Nm (100-120 kg.cm, 7-9 ft. lbs.)




11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant: Threebond 1104 or equivalent

NOTE: Do not over torque the oil pressure switch.
Tightening torque:

Oil pressure switch: 8-12 Nm (80-120 kg.cm, 6-8 ft. lbs.)