Removal
1. Remove the timing belt (see the relevant section above).
2. Remove all oil pan bolts.
3. Remove the oil pan.
4. Remove the oil receiver.
5. Remove the front cover assembly.
6. Remove the oil pump cover.
7. Remove the inner and outer gears from the front cover. The matching marks on the gears provide installation direction. Make sure the inner and outer gears are installed as shown in the figure.
8. Remove the plug and remove the spring and plunger.
Examination
Front cover
1. Check the front cover for cracks and damage: Replace if necessary.
2. Check the edges of the front cover seal for wear and damage. Replace if defective.
Oil pan and oil receiver
1. Check the oil pan for damage, breakage and cracks. Replace if there are any defects.
2. Check the oil pump for damage, breakage and cracks. Replace if defective.
Front cover and oil pump cover. Check the surfaces that contact the gears for wear (especially stepped) and damage.
Oil pump gears
1. Check the gear tooth surface for damage and wear.
2. Determine the gap between the gear wheel and the front cover.
Gear
Gap - 0.12-0.18 mm
3. Check the clearance of the pump teeth tips.
Nominal value - 0.025-0.069 mm
4. Check the axial clearance of the pump wheel.
Nominal value - 0.06-0.11 mm
Safety valve and spring
1. Check the sliding of the safety valve inserted into the front cover.
2. Check the safety valve spring for deformation or damage.
Nominal value:
- Height in free state - 46.6 mm
- Load capacity - 6.1 kg/40.1 mm
Installation
Oil pump
1. Install the inner and outer gears as shown in the figure.
2. Install the oil pump cover and tighten the bolts to the specified torque. After tightening the bolts, check that the gears rotate smoothly.
Tightening torque: Oil pump cover bolt - 8-12 Nm
3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.
Tightening torque: Valve plug - 40-50 Nm
Front cover
Install the front cover assembly with a new gasket and tighten the bolts to the specified torque.
Bolt length (A) 25 mm:
- (B) — 30 mm
- (C) — 45 mm
- (D) — 60 mm
Tightening torque: 12-15 Nm
Seal
1. Check the seal edges for wear, deformation and damage.
2. Check the extension of the snap ring.
3. Install the special tool, crankshaft oil seal guide device (09231-22100), to the front end of the crankshaft. Apply engine oil to the outer surface of the oil seal guide, use your hands to place the new oil seal at the front of the guide and install it until it contacts the front cover. Always use a new oil seal when reassembling.
4. Using a special tool to install the crankshaft oil seal (09231-22000), install the oil seal.
5. Install the crankshaft sprocket, timing belt and crankshaft pulley.
6. Install the oil receiver.
7. Clean the oil pan and cylinder block gasket surfaces.
8. Apply grease to the recesses of the oil pan flange as shown in the figure.
Warning
1) Apply the lubricant in a layer thickness of approximately 4 mm.
2) The time from the moment of applying the lubricant until the installation of the oil pan should not exceed 15 minutes.
9. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque: Oil pan bolt - 6-8 Nm