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09/16/03
2
LUBRICATING S Y S T E M
2A
. . OIL PUMP ............................ 2 :1
2A .l. . Disassembling Oil Pump . . . . . . . . . . . . . 2 : 1
2A .2. .Checking Oil Pump . . . . . . . . . . . . . . . . 2 : 1
2A .3. . Assembling Oil Pump . . . . . . . . . . . . . . . 2 : 2
2B. . CHECKING OIL PRESSURE. . . . . . . . . . . . . . . . 2 : 2
2C. . OIL FILTER ........................... 2 3
2D. . OIL PAN ............................. 2 :3
2D .1. . Removing Oil Pan . . . . . . . . . . . . . . . . . 2 : 3
2D .2. . Checking Oil Pan . . . . . . . . . . . . . . . . . . 2 : 3
2D .3. . Installing Oil Pan . . . . . . . . . . . . . . . . . . 2 : 3
2E. . OIL PRESSURE CONTROL VALVE . . . . . . . . . . 2 : 4
2F. . OIL COOLER .......................... 2 :4
2F.1. . Checking Oil Cooler . . . . . . . . . . . . . . . . 2 : 4
L 2F.2. . Replacing Bypass Valve . . . . . . . . . . . . . 2 : 4
2F.3. . Checking By-pass Valve . . . . . . . . . . . . . . 2 : 4
2C. .METERING OIL PUMP . . . . . . . . . . . . . . . . . . . 2 : 4
2G .1. .Measuring Oil Discharge . . . . . . . . . . . . . 2 : 4
2G .2. .Adjusting Metering Oil Pump . . . . . . . . . 2 : 5
2H. . OIL LEVEL SENSOR .................... 2:5
2.H-1 .Checking Oil Level Sensor . . . . . . . . . . . 2 : 5
2H.2. . Replacing Oil Level Sensor . . . . . . . . . . . 2 : 6
2
2-A. OIL PUMP
2-A-I. Disassembling Oil Pump
-
1. Remove the oil pump from the front housing as
described in Par. I-B-1 1.
2. Disassemble the oil pump in the order numbered
below.
1) Snap ring 6 ) Front inner rotor
2) Rear outer rotor 7) Key
3) Rear inner rotor 8) Shaft
4) Key 9) Spring pin (Drive out)
5) Middle plate 10) Front outer rotor
I
Fig. 2-1
2-A-2. Checking Oil Pump
1. Check the clearance betiveen the lobes of the rotors
with a feeler gauge. If the clearance exceeds the
limit, replace both rotors.
0.01 -
Standard clearance:
0.09 mm (0.0004
Clearance limit:
- 0.0035 in)
0.15 mm (0.0059 in)
2. Check the clearance between the outer rotor and
the pump body with a feeler gauge. If the clearance
exceeds the limit, replace the rotor or body.
0.20 -
Standard clearance:
0.25 mm (0.0079
Clearance Iimit:
- 0.098 in)
0.30 mm (0.0118 in)
Fig. 2-3
3. Check the end float of the rotors. Place a straight
edge across the pump body and measure the clearance
between the rotor and the straight edge.
Then place a straight edge across the matching
surface of the front housing and measure the clear-
ance between the straight edge and the front housing.
If the end float exceeds the limit, correct the pump
body by grinding.
0.03 -
Standard end float:
0.13 mm (0.0012
End float limit:
- 0.0051 in)
0.15 mm (0.0059 in)
Fig. 2-4
2 : l
2
2-A-3. Assembling Oil Pump
Assemble the oil pump in the reverse order of disas-
sembling, noting the following points.
1. Install the inner rotor and shaft assembly, and the
outer rotor into the pump body so that the tally
marks on the rotors go toward the front housing.
Fig. 2-5
2 . Install the middle plate into the pump body. Drive
in the spring pin to the body so that the spring pin
aligns the recess portion of the middle plate.
The spring pin slit should face toward the front
or rear of engine.
.
L
Fig. 2-6
3. Install the rear side inner and outer rotors into the
pump body so that the tally marks on the rotors
go toward the front housing.
Fit the snap ring on the shaft.
4. Prime the oil pump with engine oil.
5. Mount the oil pump assembly on the front housing
and fix it with bolts. Rotate the shaft by hand to
see whether it rotates smoothly.
6 . After installing, check the oil pressure as described
in Par. 2-B.
Fig. 2-7
2-B. CHECKING OIL PRESSURE
1. Drain the engine oil.
2. Remove the connecting bolt attaching the oil hose
to the rear housing and install the oil pressure con-
nector (8871 23 099) instead.
3. Connect the oil pressure gauge (49 0187 280) to the
oil pressure connector.
4. Fill the engine with engine oil.
5 . Start the engine and warm up the engine to the
normal operating temperature.
2 : 2
2
6. Take a reading of the oil pressure gauge under the
following engine conditions. L
If the oil pressure is not within the specifications, check
the following points.
1) Ensure that the oil level is between the “F” and
“L” of the dipstick gauge.
2) Check the pressure regulator and pressure control
valve.
! 3) Check the oil pump as described in Par. 2-A-2.
Fig. 2-9
2-C. OIL FILTER
To replace the oil filter, proceed as follows.
1. Remove the oil filter cartridge with a suitable wrench.
2. Apply oil onto the oil seal on a new filter cartridge.
3. Install the cartridge onto the cover and tighten the
cartridge fully by hand.
4. Start the engine and check that the joints are not
leaking. Top up with oil if necessary.
c
Fig. 2-10
2-D. OIL PAN
2-0-1. Removing Oil Pan
1. Drain the engine oil and remove the engine under
cover.
2. Disconnect the bullet connectors of the oil level
sensor.
3. Disconnect the coupler from the oil thermo unit
(Except for California).
4. Remove the oil pan.
2-D-2. Checking Oil Pan
Check the oil pan for cracks, damaged drain plug threads.
Straighten the matching surface as required.
Fig. 2-11
2-D-3. Installing Oil Pan
Install the oil pan in the reverse order of removing,
noting the following points.
1. Apply the 4 -
6 mm (0.16 -0.24 in) diameter
continuous bead of sealer (Part No. 8527 77 739)
to the mounting surface of the oil pan and place the
I - Inside \ I Outside
- - I gasket on it.
The both ends of the sealer bead should be over
lapped.
2. Apply the sealer onto the gasket as instructed in
left.
3. Tighten the oil pan attaching bolts little by little
I I
(6 8ft-lb) evenly.
-
in turn until the torque becomes 0.8 1.1 m-kg
-
Fig. 2-12
2 : 3
2
--. 2-E. OIL PRESSURE CONTROL VALVE
i Remove the pressure control valve from the front cover.
Examine the spring and the plunger for corrosion or
. - any damage. If it is severe, replace with new ones.
k- Measure the free length and replace with new spring
P
. *
if it is not in the specification.
The free length of the spring is 73 mm (2.874 in).
Fig. 2-13
2-F. OIL COOLER
2-F-1. Checking Oil Cooler
Visually inspect the oil cooler for damage, crack and
leakage.
If any defects are found, repair it by aluminum weld-
ing or replace with new one.
2-F-2. Replacing By-pass Valve
1. Drain the engine oil.
2. Remove the engine under cover.
3. Remove the cap nut and pull out the by-pass valve.
\ oil cooler \ Cap nut 4. Install the by-pass valve in the reverse order of
removing.
Fig. 2-14 5. Fill the engine with oil.
6 . Start the engine and check that the oil is not leaking
from the cap nut.
2-F-3. Checking Bypass Valve
1. Remove the by-pass valve from bottom of the oil
cooler.
2. Soak the by-pass valve in oil and heat up the oil
gradually.
3. Check the protrusion of the valve when the oil
temperature is 7OoC (158OF).
Protrusion: More than 5 mm (0.2 in)
Fig. 2-15
2-G. METERING OIL PUMP
2-6-1. Measuring Oil Discharge
Before measuring the oil discharge, check the metering
oil pump and oil hoses for leaks.
oil pump lever and washer is 0
in).
-
Make sure that the clearance between the metering
1.0 mm (0 -
0.04
1. Connect a tachometer to the engine.
2. Warm up the engine to the normal operating tem-
(0- 0.04 in)
O-’.OFnrn 1 perature.
2 : 4
2
3. Disconnect the two metering oil hoses at the car-
buret or. Y
4. Set the engine speed to 2,000 rpm and put the oil
hoses in the measuring cylinder.
5. Stop the engine after 6 minutes and check the
amount of oil discharge.
The specified amount is 2.0 -
2.5 cc/6 min.
If it is not within the specifications, adjust the meter-
ing oil pump.
Note:
While the measurements are being taken, a proper
amount of clean engine oil should be added into the
carburetor.
Fig. 2-17
2--6-2. Adjusting Metering Oil Pump
1. Loosen the lock nut of the adjusting screw.
2. Turn the adjusting screw until the proper oil dis-
charge is obtained. When the adjusting screw is
screwed in, the amount of oil discharge increases
while the amount decreases when the screw is
approx. 0.2 -
screwed out. The amount of oil discharge alters by
0.3 cc/6 min./2,000 rpm per one
turn of the adjusting screw.
3. Tighten the lock nut of adjusting screw.
4. After adjusting is completed, check the clearance
-
between the pump lever and the washer.
The clearance should be 0 1.0 mm ( 0 0.04 in).-
If necessary, adjust it by using a suitable washer. L
Fig. 2-18
k 2-H. OIL LEVEL SENSOR
2-H-1. Checking Oil Level Sensor
1. Turn the ignition switch on. The oil level warning
light comes on.
2. Start the engine and the warning light should go off.
3. Disconnect the coupler from the oil level sensor.
Ground the disconnected coupler and check to see
the warning light comes on at idle.
4. Remove the sensor.
5. Check the oil holes of the sensor whether deposits
pile up or oil holes are clogged.
/
I O i l level warnlng hght
I If necessary, clean the oil holes with solvent.
Fig. 2-19 The specified resistance is 2
30°C (50 86°F).
-
6 . Check the resistance of the sensor with an ohmmeter.
- 4 kiloohm a t 10 -
7. Connect the test lamp of the 3.4 wattage to the
sensor terminal.
8. Connect the battery charger or rectifier (the voltage
should 14V) to the test lamp and sensor.
- - -
The test lamp should light up in 10 60 seconds
at 10 30°C (50 86°F).
If the test lamp does not light up or it lights up
immediately after the connection, replace the sensor.
Fig. 2-20
2 : s
2
2-H-2. Replacing Oil Level Sensor
1. Drain the engine oil.
2. Disconnect the coupler of the sensor.
3 . Remove the sensor attaching nut and remove the
sensor.
4. Place the gasket onto the sensor.
5. Install the sensor to the oil pan with “L” mark
on the sensor downward.
t o 2.5 - 3.0 rn-kg (18 -
6 . Install the nut onto the sensor and tighten the nut
7. Connect the coupler of the sensor.
22ft-lb).
8. Fill the engine with engine oil.
9. Start the engine and check to see the oil is not leaking
i from the joining faces of the sensor.
Fig. 2-21
2 : 6
