Oil Pump: Service and Repair
Oil pump / crankshaft seal, front, replacing
Special tools:
999 5433 COUNTERHOLD 999 5433 Counterhold
998 6187 UNIVERSAL PULLER 100 998 6187 Universal Puller 100
999 5919 PULLER 999 5919 Puller
999 5455 PUNCH 999 5455 Punch
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Note! If the oil pressure is low or if there is possibly a fault with the oil pump, measure the oil pressure according to: Service information Section: 2 (21).
Remove engine components
Caution! Remove the ignition key.
Remove
- the cross stay between the suspension turrets
- the upper timing belt cover
- the servo reservoir and expansion tank. Lift up and place on top of the engine.
Warning! Ensure that no power steering fluid is spilled. Extremely flammable.
- the auxiliaries belt
- the front timing belt cover.
Position the engine according to the marking
Raise the car
- Remove the right front wheel
- Install the upper timing belt cover
- Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond
- Turn a further 1/4 turn clockwise and then back counter-clockwise until the markings correspond
- Remove the upper camshaft cover.
Remove the timing belt
- Slacken off the center screw for the belt tensioner slightly
- Hold the center screw secure. Turn the tensioner eccentric clockwise with a 6 mm Allen key to "10 o'clock"
- Remove the timing belt.
Remove the vibration damper
- Install counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold
- Counterhold and remove the crankshaft center nut
- Work the vibration damper loose and remove by hand
- Remove the camshaft belt.
Remove the crankshaft timing gear pulley
- Use universal puller 998 6187 UNIVERSAL PULLER 100 998 6187 Universal Puller 100 and two of the vibration damper screws
- Tighten both the screws by hand to stop in the pulley
- Install the puller so that the claws engage in the screws, not in the camshaft pulley.
Note! Ensure that the tool claws do not damage the pulley teeth.
When only replacing the front crankshaft seal
- Remove the old seal using a groove-cut chisel or: 999 5919 PULLER 999 5919 Puller
- Clean the mating surface
- Grease and install a new seal.
Use tool 999 5455 PUNCH 999 5455 Punch
- Press in the seal using a drift and the crankshaft center nut. As illustrated.
Note! Ensure that the crankshaft does not rotate when pressing in the crankshaft seal.
Remove the oil pump
- Remove the four oil pump screws
- Remove the oil pump.
Use a groove-cut chisel and carefully break at the stop lugs
- Clean the gasket face and the mating surfaces.
Install the oil pump
Install new oil pump
- Install a new gasket
- Carefully insert the oil pump over the end of the crankshaft.
Note! Ensure that the sealing ring in the oil pump is not damaged during installation
- Install 4 new screws as guides
- Pull in the oil pump with drift 999 5455 PUNCH 999 5455 Punch and the crankshaft center nut.
Note! Ensure that the crankshaft does not rotate when drawing in the pump.
- Tighten the screws crosswise. Tighten to 10 Nm
- Install the crankshaft timing gear pulley.
Carefully tap alternately around the pulley until end position is reached.
Note! The timing gear pulley can only be in one position on the splines on the end of the crankshaft.
Install the vibration damper
Install the vibration damper.
Tighten the center nut. Tighten to 180 Nm.
Use counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold.
Remove the counterhold. Tighten the screws. Tighten to 25 Nm.
Angle-tighten 30°. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Install the timing belt
Install the upper timing belt cover.
Check that the markings on the crankshaft and camshaft timing gear pulley correspond.
Install the belt in the following order:
- crankshaft
- the idler pulley
- intake camshaft
- exhaust camshaft
- water pump
- belt tensioner.
Tighten the timing belt
This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C/68°F.
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Carefully turn the crankshaft clockwise until the timing belt is in the tensioned position (tensioned between the intake cam, idler pulley and crankshaft).
Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Turn the eccentric back until the indicator reaches the marked position in the center of the window.
Hold the eccentric secure and tighten the center screw. Tighten to 20 Nm. Ensure that the indicator is in the correct position.
Press the belt to see that the indicator on the tensioner moves easily.
Position the upper camshaft cover.
Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond.
Check that the indicator on the belt tensioner is within the marked position.
Install
- the nuts for the cover in the fender liner
- the wheel. See Installing wheels Service and Repair.
Finishing
Install:
- front timing belt cover.
Tighten to 12 Nm
- the upper timing belt cover
- the auxiliaries belt
- the expansion tank and servo reservoir.
Note! Ensure that the hoses are correctly positioned.
- the engine stabilizer brace. Tighten the screws at the suspension turrets. Tighten to 50 Nm. Tighten the engine bracket screw. Tighten to 80 Nm.
Carry out a function test
- Check the oil level and top up if required
- Start the engine
- Check that there is no oil leakage.
Stop the engine and give the oil time to run down into the oil trough.
Then check the oil level.
Top up if necessary.
Wipe the engine compartment clean.
Ensure that the steering wheel and gear selector lever are clean.