Oil Pump: Service and Repair
SPECIAL TOOLS- Counterhold tool No. 999 5433, or equivalent
- Seal Installer tool No. 999 5455, or equivalent
PROCEDURE
1. Remove:
- auxiliaries drive belt
- front transmission cover
- cooling fan
- splash guard under engine
- Drain coolant.
- Remove radiator.
2. Align camshafts/crankshaft with timing marks
- Turn crankshaft clockwise until timing marks on camshaft pulleys/transmission mounting plate and crankshaft pulley/ oil pump housing are aligned.
- Remove upper transmission cover.
3. Remove vibration damper
- Remove mounting bolts (four).
- Attach Counterhold tool No. 999 5433, or equivalent.
- Remove centre nut.
- Remove Counterhold tool No. 999 5433, or equivalent.
- Remove vibration damper.
4. Remove timing belt
- Remove tensioner upper mounting bolt. Slacken lower mounting bolt.
- Twist tensioner until plunger is free.
- Remove lower mounting bolt.
- Remove belt.
5. Check tensioner
- Inspect component for signs of leakage.
- Compress tensioner using tool 5456.
Mount tensioner in tool and tighten centre nut fully.
Wait until compression has taken place and insert 2 mm locking pin in plunger.
NOTE: Tensioner must be replaced if leakage is observed, if plunger offers no resistance when depressed or if plunger cannot be depressed.
6. Remove crankshaft pulley
- Use puller.
7. When replacing crankshaft front seal only:
- Remove old seal using screwdriver.
- Clean seat.
- Install new seal using seal installer tool No. 999 5455, or equivalent.
Grease seal.
- Press in seal using crankshaft centre nut.
- Proceed to step 13.
8. Remove oil pump
- Remove all bolts.
- Clean joint face and mating surfaces.
9. Dismantle oil pump
- Clean and inspect all components
- Inspect for damage and wear, with particular attention to half-moon insert (between suction and delivery sides).
Replace complete pump if faults are found.
- Separate parts are available for relief valve.
Spring Tension (Part 1 Of 2):
10. Test relief valve springs
Pressure Relief Valve Spring: P/N 1397819 early type 1992 - 1993
Load At Length:
Load = 0 N (no load): Length = 76.22 mm
Load = 52 ± 4 N: Length = 56.10 mm
Load = 85 ± 8 N: Length = 39.90 mm
Pressure Relief Valve Spring: P/N 9135202 late type 1993 - 1998
Load At Length:
Load = 0 N (no load): Length = 76.22 mm
Load = 59 ± 4 N: Length = 56.10 mm
Load = 108 ± 8 N: Length = 39.90 mm
11. Place pump wheels in housing and check clearance/play
- Place large pump wheel in position with marking facing upwards.
- Place small wheel in position.
- Check clearance/play.
Replace complete pump if excessive.
Reassemble pump.
12. Install oil pump
- Transfer snow shield.
- Use new gasket.
- Use seal installer tool No. 999 5455, or equivalent, when installing pump.
Use bolts as guides.
Pull in pump using crankshaft centre nut.
NOTE: Use thread locking compound part No. 1 161 056, or equivalent, on bolts
- Tighten bolts alternately to 10 Nm (7 ft. lbs.).
- Install crankshaft pulley using centre bolt and spacer.
13. Install timing belt
- Place belt around crankshaft pulley and right-hand idler.
- Place belt over camshaft pulleys.
- Position belt around water pump and press over tensioner pulley.
- Install tensioner and tighten bolts to 25 Nm (18 ft.lb).
- Remove locking pin.
14. Install vibration damper
- Tighten center nut to 300 Nm (221 ft. lbs.) using 30 mm socket.
- Use counterhold tool No. 999 5433, or equivalent.
- Tighten bolts (four) to 35 Nm (26 ft. lbs.) and through further 60 degrees.
15. Install tensioner
- Install upper transmission cover
- Turn crankshaft through two revolutions and check that timing marks on crankshaft and camshaft pulleys are correctly aligned
- Install ignition coil cover
16. Install:
- radiator
- front transmission cover
- auxiliaries drive belt
- splash guard under engine
- cooling fan
Check operation, inspect for leaks
- Fill cooling system with coolant.
- Check oil level.
- Test-run engine.
- Inspect for leaks.
- Check coolant level