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.






5. Remove the front case assembly.
6. Remove the oil pump cover.
7. Remove the inner and outer gears from the front case.

NOTE: The mating marks on the inner and outer gears indicate the direction of installation, note position for later assembly.

8. Remove the plug and remove the relief spring and relief plunger.

INSTALLATION

NOTE: Always replace the Front Crankshaft Seal.

1. Install the outer and inner gears into the front case.

NOTE: Make sure that the inner and outer gears are installed with mating marks as noted during removal.






2. Install the oil pump cover and tighten the bolts to 6-9 Nm (60-90 kg.cm, 4-6.6 ft. lbs.).

NOTE: After the bolts have been tightened, check to ensure that the gear turns smoothly.

3. Install the relief valve, spring and plug, then tighten the plug to 40-50 Nm (400-500 kg.cm, 29-36 ft. lbs.).






4. Install the front case assembly with a new gasket, insert bolts by length as shown in the illustration, then tighten the bolts to 20-27 Nm (200-270 kg.cm, 14.5-19.8 ft. lbs.).
Bolt length:
(A)25 mm (0.98 inch)
(B)20 mm (0.787 inch)
(C)38 mm (1.496 inch)
(D)45 mm (1.771 inch)
5. Install the crankshaft sprocket, timing belt and crankshaft pulley.
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 approximately 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 6-8 Nm (60-80 kg.cm, 4-6 ft. lbs.).