Oil Pump: Service and Repair

Special Tools:
- Counterhold tool No. 999 5433, or equivalent
- Drift tool No. 999 5455, or equivalent

NOTE:
- For additional information on special tools and equipment used in this procedure, refer to Tools For Engine Service and Repair. Tools and Equipment
- If low oil pressure/oil pump faults are suspected take oil pressure reading. Testing and Inspection
- Carry out steps 1, 2 and 4 of Timing Belt Replacement. Service and Repair

Procedure





1. Remove vibration damper:
- Remove splashguard.
- Remove vibration damper, use counterhold tool No. 999 5433, or equivalent.





2. Remove crankshaft belt pulley:
- Use universal puller and two vibration damper bolts.
- Tighten two screws by hand until they contact the pulley.
- Install puller so that the claws pull the bolts (not the pulley).

NOTE: Make sure that the claws do not damage the pulley teeth.





3. If replacing front oil pump seal only:
- Remove the old seal using a groove-cut chisel.
- Clean mating surfaces.
- Replace seal, use drift tool No. 999 5455, or equivalent, grease seal.
- Press in seal using the crankshaft center nut.





4. Remove the oil pump:
- Undo the four oil pump bolts.
- Carefully pry out oil pump, use a groove-cut chisel behind pry lugs.
- Clean seal face and mating surfaces.





5. Dismantle oil pump:
Clean and check all components:
- Check for wear and damage, pay particular attention to the crescent shaped insert (surface between suction and delivery sides).
If components are defective replace pump.
- Separate parts are available for the relief valve.

Spring Tension (Part 1 Of 2):

6. Test relief valve spring Load (N):
- Load (N) / Length (mm)
0: 82.13 mm
59 ± 4: 56.10 mm
108 ± 8: 39.90 mm
Relief valve opens: 0.60 MPa (85 psi)





7. Install pump wheel in housing and check for play:
- Place large pump wheel in housing with markings upwards.
- Install the small pump wheel.
- Check for play. If there is too much play replace pump. Assemble pump

NOTE:
- If the play between the outside surfaces and the oil pump housing are greater than 0.35 mm and oil pressure is below 1 bar (14 psi) at 100°C (212°F), the oil pump should be replaced.
- Measure play with a feeler gauge.





8. Install oil pump:
- Use new gasket.
- Use drift tool No. 999 5455, or equivalent when installing pump.
Use screws as guide.
- Pull in the oil pump with the crankshaft center nut.
- Tighten screws crosswise to 10 Nm (84 inch lbs.).
- Install crankshaft belt pulley using center nut and a spacer.





9. Install timing belt:
- Install belt tensioner screws, tighten to: 25 Nm (18 ft lb).
- Place belt around the crankshaft and right idler pulley.
- Place belt over camshaft pulley.
- Place belt around water pump and press belt over the tensioner pulley.





10. Install vibration damper:
- Pull locking pin out of belt tensioner.
- Install vibration damper.
- Tighten center nut to 180 Nm (133 ft lb).
- Use counterhold 999 5433, or equivalent.
- Remove counterhold (999 5433, or equivalent) and tighten screws to: 25 Nm (18 ft lb).
- Install upper timing cover.
- Turn the crankshaft two revolutions and check that timing marks on crankshaft and camshaft pulley are aligned.
- Install spark plug cover.





11. Install:
- vibration damper guard front timing cover
- auxiliaries belt
- two fuel pipe clips
- expansion tank
- wing liner and wheel
Test run engine.