Oil Pump Replacement (First Design)

REMOVAL PROCEDURE

- TOOLS REQUIRED
- J 35268-A Camshaft/Front Main Seal Installer
- J 36660 Torque/Angle Meter
- J 42098 Crank Hub Torx Socket
- J 42065 Crank Hub Holding Tool

1. Disconnect the negative battery cable.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Recover the A/C system.
3. Drain the coolant.
4. Remove the intake air resonator.
5. Remove the front timing belt cover.
6. Remove the timing belt.
7. Remove the rear timing belt cover.
8. Remove the A/C compressor.
9. Remove the A/C compressor and power steering pump bracket bolts.
10. Position the A/C compressor and power steering pump bracket out of the way of the oil pump housing and secure.





11. Remove the generator lower mounting bolt (3).
12. Loosen the upper generator mounting bolt (6).
13. Pivot the generator out of the way and secure.
14. Remove the oil pan.
15. Remove the upper oil pan housing.





16. Mount the J 42065 to the crankshaft drive gear.
17. Use the J 42098 to remove the crankshaft drive gear bolt.





18. Remove the crankshaft drive gear.





19. Remove the six oil pump bolts.
20. Remove the oil pump.
21. Remove the front main oil seal and collar from the oil pump.
22. Clean the oil pump sealing surfaces if the pump is to be reinstalled.





23. Clean the engine block (1) and the upper oil pan housing sealing surfaces.
24. Ensure all of the old sealant, gasket material, residual oil is removed and the guide pins (2) are in place.

INSTALLATION PROCEDURE





1. Coat the pump side of the new oil pump gasket in the crosshatched areas shown in the illustration with a thin, even coating of anaerobic sealant GM P/N 1052942 or equivalent. (Note the tightening sequence for the bolts).

Important: Do not cover and/or restrict the gasket openings with excess sealant.

2. Install the oil pump gasket.





3. Install the oil pump and align with the guide pins (2).
4. Apply thread sealant GIVI P/N 12346004, or equivalent, to the six oil pump bolts and install the bolts.

Notice: Refer to Fastener Notice in Service Precautions.

- Tighten the oil pump bolts, using the sequence shown, to 8 Nm (71 inch lbs).

5. Install the timing belt idler pulley and washer for camshafts 3 and 4.

Important: The timing belt is NOT installed at this point, the camshaft 3 and 4 idler pulley bolt is torqued to specification to allow for proper compression of the oil pump gasket.

- Tighten the timing belt idler pulley locking nut to 40 Nm (30 ft lbs).





6. Release and pivot the generator into place and install the generator lower mounting bolt (3).
Tighten
- Tighten the generator lower and upper bolts to 40 Nm (30 ft lbs).
- Re-tighten the six oil pump bolts, using the sequence shown, to 9 Nm (80 inch lbs).

7. Remove the timing belt idler pulley and washer for camshafts 3 and 4.
8. Install the oil pump collar.





9. Install the front main oil seal. Coat the lip of the front main oil seal with a small amount of GIVI P/N 1052497 chassis grease or equivalent to aid in installation.
10. Use the J 35268-A to install the front main oil seal.
11. Ensure the front main oil seal if fully and evenly seated.
12. Install the crankshaft drive gear.
13. Install a new crankshaft drive gear bolt.
- Tighten the crankshaft drive gear bolt, while counterholding with J 42065, to 250 Nm (184 ft lbs) + 45 degrees + 15 degrees.

14. Install the upper oil pan housing.
15. Install the oil pan.
16. Position the A/C compressor and power steering pump bracket.
17. Install the A/C compressor and power steering pump bracket bolts.
- Tighten the A/C compressor and power steering pump bracket bolts to 40 Nm (30 ft lbs).

18. Install the A/C compressor.
19. Install the rear timing belt cover.
20. Install the timing belt.
21. Install the front timing belt cover. Refer
22. Install the intake air resonator.
23. Charge the A/C system.
24. Reconnect the negative battery cable and reprogram the applicable accessories.
25. Fill the cooling system.