Oil pump and upper oil pan housing
Removal
1. Remove the oil pan as described in paragraph 12.
2. Remove the timing belt as described in paragraph 7. Also remove the crankshaft sprocket and front tension roller (see Figure 13.2).
Figure 13.2. Removing the front timing belt tension roller.
3. Loosen the mounting bolts and remove the accessory drive belt tensioner bracket under the generator (see Figure 13.3).
Figure 13.3. Removing the accessory drive belt tensioner bracket located under the generator.
4. Loosen the mounting bolt, then remove the oil dipstick tube from the upper crankcase of the oil pan. Remove the sealing ring from the dipstick tube (see Figure 13.4).
Figure 13.4. Removing the sealing ring from the dipstick tube.
5. If necessary, remove the oil level sensor. Also, if necessary, you can remove the pressure relief valve from the upper crankcase of the oil pan (see Figure 13.5).
Figure 13.5. Removing the pressure relief valve from the upper crankcase of the oil pan.
6. Unscrew the flange mounting bolts and support mounting nuts; remove the oil receiver tube with the gasket (see Figure 13.6).
Figure 13.6. Removing the oil receiver tube and its gasket.
7. Loosen the mounting bolt and remove the oil pan reflector plate (see Figure 13.7).
Figure 13.7. Removing the oil pan insulator.
8. Loosen the mounting bolts and remove the upper oil pan housing from the bottom of the engine cylinder block, then remove the two sealing gaskets. If they are "grown", carefully separate them from the body using a screwdriver or plastic knife. Be careful not to damage the mating surfaces of the oil pan and block to avoid causing leaks. If necessary, remove the oil filter housing from the oil pan housing and remove the sealing gasket (see figure 13.8, a, b).
Figure 13.8,a. Remove the oil filter housing...
Figure 13.8, b....and remove the sealing rings.
9. Loosen the mounting bolt and remove the crankshaft position sensor from the oil pump housing (see Figure 13.9).
Figure 13.9. Crankshaft position sensor on the oil pump cover.
10. Loosen the mounting bolts and remove the oil pump, taking it out of the cylinder block above the crankshaft. If it doesn't come out, gently pry it up from below with a screwdriver. Remove the sealing gasket (see Figure 13.10).
Figure 13.10. Removing the oil pump gasket.
Examination
11. Checking the pump is described in Chapter 2A. Install a new crankshaft oil seal into the oil pump housing as described in paragraph 8 (see Figure 13.11, a-d).
Figure 13.11,a. Checking the outer rotor/housing gap...
Figure 13.11, b....and the gap between the inner rotor cam and the outer rotor using a set of flat feeler gauges.
Figure 13.11, c. Knock out the old oil seal from the inside of the oil pump cover...
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Figure 13.11, d....using a mandrel, press the new seal flush with the outer surface of the cover.
Installation
12. If you are replacing the oil pump, remove the mounting stud from the old pump and transfer it to the new pump.
13. Clean the mating surfaces of the oil pump and cylinder block, then apply a 2-4 mm wide bead of sealant to the oil pump cover, avoiding the holes for the mounting bolts from the inside (see figure 13.13,a,b).
Figure 13.13,a. Apply sealant to the oil pump cover as shown in this diagram.
Figure 13.13,b. Cut the tube nozzle so that the width of the sealant strip is 2-4 mm.
Place a new gasket around the oil pump rotor.
14. Fill the cavities of the oil pump in the cylinder block with engine oil, then install the oil pump on the guide bushings and tighten the mounting bolts to the specified torque (see Figure 13.14, a-c).
Figure 13.14,a. Fill the voids in the oil pump housing with engine oil...
Figure 13.14, b....then install the housing into the cover/oil pump...
Figure 13.14, g....on the guide bushings.
Make sure the oil pump drive sprocket rotates freely.
15. Install the crankshaft position sensor and tighten the mounting bolts to the specified torque.
16. Clean the mating surfaces of the upper oil pan housing and the cylinder block, then apply a 4-7 mm wide bead of sealant to the upper oil pan housing (see figure 12.8, a, b). Pay attention to which side the sealant strip should go around the holes (see Figure 13.16).
Figure 13.16. Apply a 4-7 mm wide bead of sealant to the mating flange of the upper oil pan housing.
17. Press in two new sealing rings, install the upper oil pan housing in its place and tighten the mounting bolts to the specified torque (see figure 13.17, a, b).
Figure 13.17,a. Press new sealing rings into the corresponding grooves...
Figure 13.17, b....then install the upper oil pan housing.
18. If removed, install the oil filter housing with a new gasket and tighten the nuts/bolts to the specified torque.
19. Install the oil pan deflector plate and tighten the mounting bolt to the specified torque.
20. Install the oil pickup tube together with a new gasket and tighten the bolts/nuts to the specified torque.
21. Install the oil level sensor and tighten the mounting bolts to the specified torque.
22. Install the oil dipstick tube together with the new sealing ring and tighten the mounting bolt.
23. Install the accessory drive belt adjuster bracket and tighten the mounting bolts to the specified torque.
24. Install the timing belt, crankshaft sprocket and front tensioner roller as described in paragraph 7.
25. Install the oil pan as described in paragraph 12.