Oil Pump: Service and Repair
REMOVAL
1. DRAIN ENGINE OIL
2. REMOVE FRONT EXHAUST PIPE
Remove 4 bolts, 2 compression springs, 2 gaskets and front exhaust pipe.
3. REMOVE RH ENGINE UNDER COVER
4. REMOVE OIL PAN
a Remove the 12 bolts and 2 nuts.
b Insert the blade of SST between the crank case and oil pan, and timing chain cover and oil pan, cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE: Be careful not to damage the contact surface of the timing chain cover, crank case and oil pan.
5. REMOVE AIR CLEANER ASSEMBLY
6. REMOVE ABS ACTUATOR
7. REMOVE RH ENGINE MOUNTING INSULATOR
8. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET
9. REMOVE OIL PUMP DRIVE CHAIN AND SPROCKETS
a Set the crankshaft key into the left horizontal position.
b Remove the bolt, chain tensioner plate and spring.
c Using a screwdriver, hold the oil pump drive shaft sprocket as shown in the illustration.
d Remove the nut, 2 sprockets and drive chain.
10. REMOVE OIL PUMP
Remove the 3 bolts, oil pump and gasket.
DISASSEMBLY
1. REMOVE RELIEF VALVE
Remove the plug (1), spring (2) and relief valve (3).
2. REMOVE DRIVE AND DRIVEN ROTORS
Remove the 7 bolts, pump body cover, drive and driven rotors.
INSPECTION
1. INSPECT OIL JET
Check the oil jet for damage or clogging.
If necessary, replace the cylinder block.
2. 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.
3. INSPECT DRIVE AND DRIVEN ROTORS
a Place the drive and driven rotors into the oil pump body.
b Inspect for the tip clearance.
Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance: 0.080 - 0.160 mm (0.0031 - 0.0063 inch)
Maximum tip clearance: 0.35 mm (0.0138 inch)
If the tip clearance is greater than maximum, replace the rotors as a set.
c Inspect for the 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 - 0.085 mm (0.0012 - 0.0033 inch)
Maximum side clearance: 0.16 mm (0.0063 inch)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.
d Inspect for the body clearance.
Using a feeler gauge, measure the clearance between the driven rotor and body.
Standard body clearance: 0.100 - 0.170 mm (0.0039 - 0.067 inch)
Maximum body clearance: 0.325 mm (0.0128 inch)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.
4. INSPECT OIL PUMP DRIVE CHAIN AND OIL PUMP SPROCKETS
a Using vernier calipers, measure the length of the 8 links with the chain dully stretched.
Maximum chain elongation: 52.4 mm (2.063 inch)
If the elongation is greater than maximum, replace the chain.
HINT: Make the same measurements pulling at 3 or more places selected at random.
b Wrap the chain around the oil pump sprocket.
c Using vernier calipers, measure the sprocket diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for measuring
Minimum sprockets diameter (w/ chain): 48.2 mm (1.898 inch)
If the diameter is less than minimum, replace the chain and 2 sprockets.
5. INSPECT CHAIN TENSIONER PLATE
Measure the chain tensioner plate wear.
Maximum wear: 0.5 mm (0.020 inch)
If the wear is greater than maximum, replace the chain tensioner plate.
REASSEMBLY
1. INSTALL DRIVE AND DRIVEN ROTORS
a Place the drive and driven rotors into the pump body with the marks facing the pump body cover side.
b Install the pump body cover with the 7 bolts.
Torque: 8.8 Nm (90 kgf-cm, 80 inch lbs.)
2. INSTALL RELIEF VALVE
Insert the relief valve (1) and spring (2) into the pump body hole, and install the plug (3).
Torque: 49 Nm (500 kgf-cm, 35 ft. lbs.)
INSTALLATION
1. INSTALL OIL PUMP
Install a new gasket and the oil pump with the 3 bolts.
Torque: 18.6 Nm (190 kgf-cm, 14 ft. lbs.)
2. INSTALL DRIVE CHAIN AND SPROCKETS
a Set the crankshaft key into the left horizontal position and turn the cutout of the drive shaft to the top.
b Set the chain on the 2 sprockets as shown in the illustration.
HINT:
- Set the mark on the oil pump drive sprocket at the colored link in the chain.
- Set the mark on the oil pump drive shaft sprocket at the colored link.
c Install the chain and 2 sprockets with the nut.
Torque: 29.5 Nm (300 kgf-cm, 20 ft. lbs.)
3. INSTALL CHAIN TENSIONER
Install the spring and plate with the bolt.
Torque: 12 Nm (120 kgf cm, 9 ft. lbs.)
4. INSTALL OIL PAN
a Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain/crank case and oil pan.
- 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.
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.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 4.0 - 4.5 mm (0.16 - 0.18 inch) opening.
HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 3 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 12 bolts and 2 nuts.
Torque: 9 Nm (90 kgf-cm, 80 inch lbs.)
5. INSTALL CRANKSHAFT TIMING SPROCKET AND TIMING CHAIN
6. INSTALL RH ENGINE MOUNTING INSULATOR
7. INSTALL ABS ACTUATOR
8. INSTALL AIR CLEANER ASSEMBLY
9. INSTALL FRONT EXHAUST PIPE
Install 2 new gaskets and front exhaust pipe with the 2 compression springs and 4 bolts.
Torque:
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt A
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolt B
10. INSTALL ENGINE UNDER COVER
11. FILL ENGINE WITH OIL
12. START ENGINE AND CHECK FOR LEAKS
13. RECHECK ENGINE OIL LEVEL