Oil Pump: Service and Repair

REMOVAL

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

1. REMOVE CRANKSHAFT TIMING PULLEY
2. 4WD:
REMOVE FRONT DIFFERENTIAL
3. DRAIN ENGINE OIL
4. A/T:
REMOVE OIL COOLER TUBE AND CLAMP
5. REMOVE REAR END COVER AND DUST COVER
6. DISCONNECT STARTER WIRE CLAMP
7. REMOVE CRANKSHAFT POSITION SENSOR
8. REMOVE OIL PAN





a. Remove the 17 bolts and 2 nuts.





b. Using Special Service Tool (SST) and a brass bar, separate the oil pan from the cylinder block.
SST 09032-00100

HINT: When removing the oil pan, be careful not to damage the oil pan flange.





9. REMOVE OIL STRAINER
Remove the bolt, 3 nuts and oil strainer and gasket.
10. REMOVE OIL PAN BAFFLE PLATE
Remove the bolt, 2 nuts and oil pan baffle plate.





11. REMOVE OIL PUMP
a. Remove the 8 bolts, ground strap and oil pump.
b. Using a plastic-faced hammer, carefully tap the oil pump body.
c. Remove the O-ring from the cylinder block.

DISASSEMBLY





1. REMOVE DRIVEN AND DRIVE ROTORS
a. Remove the 8 screws and pump body cover.
b. Remove the drive and driven rotors.





2. REMOVE RELIEF VALVE
a. Unscrew the relief valve plug and gasket.
b. Remove the spring and relief valve.

INSPECTION





1. INSPECT BODY CLEARANCE
Using a thickness gauge, measure the clearance between the driven rotor and pump body.
Standard clearance: 0.10 -0.18 mm (0.0039 - 0.0069 inch)
Maximum clearance: 0.30 mm (0.0118 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set and/or pump body.





2. INSPECT TIP CLEARANCE
Using a thickness gauge, measure the clearance between the drive and driven rotors.
Standard clearance: 0.11 - 0.24 mm (0.0043 - 0.0094 inch)
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set.





3. INSPECT SIDE CLEARANCE
Using a thickness gauge and precision straight edge, measure the side clearance, as shown.
Standard clearance: 0.03 - 0.09 mm (0.0012 - 0.0035 inch)
Maximum clearance: 0.15 mm (0.0059 inch)
If the clearance is greater than the maximum, replace the oil pump rotor set and/or pump body.





4. INSPECT RELIEF VALVE
Coat the relief valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If the valve does not fall smoothly, replace the valve and/or oil pump assembly.

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL. Refer to Engine; Cylinder Block Assembly; Service and Repair; Inspection and Replacement.

REASSEMBLY





1. INSTALL RELIEF VALVE
Install the relief valve, compression spring, new gasket and plug.
2. INSTALL DRIVEN AND DRIVE ROTORS
a. Install the drive and driven rotor.





HINT: Place the drive and driven rotor into pump body with the marks facing the pump body cover side.





b. Install the pump body cover with 8 screws.
Torque: 10 Nm (105 kgf-cm, 8 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 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
^ Install nozzle that has been cut out 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 5 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 into the groove of cylinder block.





d. Install the oil pump to the crankshaft with the spline teeth of the drive rotor engaged with the large teeth of the crankshaft.





e. Install the oil pump with the 8 bolts, and ground strap.
Torque:
Bolt A: 20 Nm (200 kgf-cm, 15 ft. lbs.)
Bolt B: 42 Nm (420 kgf-cm, 31 ft. lbs.)
2. INSTALL CRANK SHAFT POSITION SENSOR
3. INSTALL OIL PAN BAFFLE PLATE
4. INSTALL OIL STRAINER
Place a new gasket and install the oil strainer.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
5. CLEAN OIL PAN.
Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the, oil pan, cylinder block and sealing grooves.
^ Using a razor blade and gasket scraper, remove all the remaining seal packing (FIPG) material from the gasket surfaces.
^ Thoroughly clean all components to remove all the loose material.
^ Clean both sealing surfaces with a non-residue solvent.

NOTICE: Do not use a solvent which will affect the painted surfaces.





6. INSTALL OIL PAN
a. Apply seal packing to the oil pan, as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
^ Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.

HINT: Avoid applying an excess amount to the surface.
^ If parts are not assembled within 5 minutes of applying the seal packing, the effectiveness of the seal packing is lost and the seal packing must be removed and reapplied.
^ Immediately remove the nozzle from the tube and reinstall the cap after using the seal packing.

b. Install the oil pan with the 2 nuts and 17 bolts.
Torque: 7.6 Nm (78 kgf-cm, 67 inch lbs.)
7. INSTALL REAR END COVER AND DUST COVER
8. CONNECT STARTER WIRE CLAMP
9. A/T:
INSTALL OIL COOLER TUBE AND CLAMP
10. INSTALL CRANKSHAFT TIMING PULLEY
11. 4WD:
INSTALL FRONT DIFFERENTIAL
12. FILL WITH ENGINE OIL
13. START ENGINE AND CHECK FOR LEAKS
14. INSTALL ENGINE UNDER COVER
15. RECHECK ENGINE OIL LEVEL