Engine Lubrication: Service and Repair

Lubricating system
Oil pump (in situ)
To remove
1 Remove the cover over the intake manifold.





2 Raise the car. Remove the right-hand front wheel and detach the power steering pump from the sub frame.
3 Insert a Wedge 83 95 238 between the oil sump and sub frame so that it can later be driven in to raise the engine on assembly.
4 Remove the right-hand engine mounting with yoke.





5 Take the strain off the belt tensioner with the aid of a ratchet handle extension and insert a 3 mm hexagon key in the hole, shown.

IMPORTANT: Exercise the utmost care to ensure that the belt tensioner does not break at its end position!

6 Remove the flywheel cover plate and in Flywheel locking segment 63 94 86 841.





7 Remove the crankshaft pulley. Remove and clean the oil sump circle. Use Circle pliers 82 93 086 Lift off the pump(+ cover with large multi grip pliers. Remove the pump gears.

NOTE: Two bent welding rods can be used to assist in the removal of the outer pump gear.

To fit





1 Make sure that the marking on the oil pump ring gear is facing out and the pump gear with flange facing in. Check the politic and condition of the O-ring, lubricate with Vaseline.
2 Oil and fit the pump gears, fit the pump cover in correct position using the locating arrows.
3 Fit the circle with the chamfer facing outwards and the opening downwards.





4 Fit the crankshaft pulley.
Tightening torque 175 Nm (130 ft. lbs.).





5 Remove the flywheel locking segment and fit the flywheel cover plate.
6 Drive in the wedge to raise the engine.





7 Fit the drive belt, check its position on all the pulleys and remove the strain-relieving hexagon key.





8 Fit the right-hand engine mounting.
Tightening torque 50 Nm (37 ft. lbs.).
9 Remove the wedge and fit the power steering pump pipe.
10 Fit the wheel.
Tightening torque: 110 Nm (80 ft. lbs.).

IMPORTANT: The wheels must be hanging freely when the wheel bolts are tightened.

11 Start the engine and run it at idling speed for a while.
12 Switch off the engine and check that the belt is correctly positioned.
13 Fit the cover over the intake manifold.

Oil sump (in car)
To remove
1 Remove the upper engine cover.
2 Remove the dipstick and place a rag in the tube. Remove the oxygen sensor cables.
3 Remove the turbo's bypass pipe and the heat shield over the exhaust manifold.
4 Undo the two upper nuts on the exhaust pipe.
5 Raise the car and remove the lower engine cover. 6 Remove the remaining mountings and remove the front exhaust pipe. 7 Remove the cover plate from the gearbox.
8 Drain the engine oil.
9 Disconnect the crankcase breather hose from the oil sump.
10 Remove the bolts on the oil sump and lower the sump.

To fit
1 If the sump is changed, transfer the splash guard and pipe to the new sump. Use new O-rings.
2 Ensure the oil sump contains no dirt or contaminants. Clean the sealing surfaces on the engine and sump with a gasket scraper and benzene.
3 Apply an even, 2 mm thick bead of flange sealant, part no. 93 21 795 to the sealing surfaces of the oil sump.
4 Check that the pipe to the oil adapter is securely in place and that it positioned correctly on the oil sump. Change the O-rings if necessary.
5 Lift up and position the oil sump. Thread all the bolts.
6 Tighten the oil sump bolts.
Tightening torque 22 Nm (16 ft. lbs.)
7 Fit the crankcase ventilation hose. 8 Fit the gearbox cover plate.
9 Clean the joints, grease the studs of the turbocharger with Molycote 1000, part no. 30 20 971 and fit the exhaust pair
10 Check that the oil plug has been removed and lower the car.
11 Tighten the upper bolts on the exhaust pipe.
12 Plug in the oxygen sensor cables.
13 Fit the heat shield over the exhaust manifold and turbo's bypass pipe.
14 Fill with engine oil and put back the dipstick.
15 Fit the upper engine cover.
16 Run the engine until warm, raise the car and check the integrity around the sealing surface.
17 Fit the lower engine cover.
18 Lower the car, check the oil level and top up as necessary.

Oil sump (in car) B235R manual
To remove
1 Remove the upper engine cover.
2 Remove the dipstick and place a rag in the tube. Remove the oxygen sensor cables.
3 Remove the turbo's bypass pipe and the heat shield over the exhaust manifold.
4 Undo the two upper nuts on the exhaust pipe.
5 Raise the car and remove the lower engine cover.
6 Remove the remaining mountings and remove the front exhaust pipe.
7 Drain the engine oil.
8 Disconnect the crankcase breather hose from the oil sump.
9 Mark the position of the hole 35 mm from the edge as illustrated prior to drilling using a center punch.
10 Drill first with a small bit. Then drill using a hole saw 0 30 mm, angled approximately 450 upwards, to prepare access to the concealed bolts of the oil sump.
11 Remove the cover plate and the oil sump bolts.
12 Using a pry bar as illustrated, carefully remove the oil sump.
13 Wipe away any oil and cuttings. Clean all surfaces thoroughly.

To fit
1 Transfer the splash guard and pipe to the new sump. Use new O-rings.
2 Knock out the holes in the new sump using a ball peen hammer. File the holes and clean off the filings.
3 Ensure the oil sump contains no dirt or contaminants. Clean the sealing surfaces on the engine and gearbox with a gasket scraper and benzene.
4 Apply an even, 2 mm thick bead of flange sealant, part no. 93 21 795 to the sealing surfaces of the oil sump.
5 Check that the pipe to the oil adapter is securely in place and that it positioned correctly on the oil sump. Change the O-rings necessary.
6 Position the cover plate.
7 Carefully bend aside using a pry bar and position the oil sump. Thread all the bolts.
8 Firstly, lightly tighten the bolts in the engine block. Then tighten the three bolts to the gearbox. Tighten the remaining bolts of the oil sump finishing with the two bolts in the reinforcement.
Tightening torque 22 Nm (16 ft. lbs.)
9 Fit the crankcase ventilation hose.
10 Clean the joints, grease the studs of the turbocharger with Molycote 1000, part no. 30 20 971 and fit the exhaust pipe.
11 Check that the oil plug has been removed and lower the car.
12 Tighten the upper bolts on the exhaust pipe.
Tightening torque 25 Nm (18 ft. lbs.)
13 Plug in the oxygen sensor cables.
14 Fit the heat shield over the exhaust manifold and turbo's bypass pipe.
15 Fill with engine oil and put back the dipstick.
16 Fit the upper engine cover.
17 Run the engine until warm, raise the car and check the integrity around the sealing surface.
18 Fit the lower engine cover.
19 Lower the car, check the oil level and top up as necessary.

Oil filter adapter housing
To remove





1 Raise the car, remove the cover and detach the oil filter.
2 Detach the oil hoses from the adapter housing and disconnect the turbocharger's oil pipe.
3 Remove the adapter housing.

To fit





1 Clean and inspect the sealing surfaces.
2 Change the O-ring.
3 Lubricate the sea] and fit the adapter housing to the engine block, using Locative 518.
4 Connect the oil hoses and the turbocharger pipe.
5 Check that the oil plug is properly tightened, fit the oil filter and cover and lower the car.
6 Fill up with motor oil, warm up the engine and check for leaks.

Engine oil thermostat
To remove
1 Raise the car, remove the cover and unscrew the plug.





2 Remove the adapter housing or loosen the A/C-compressor slightly)
3 Extract the spring and thermostat.

To fit





1 Fit the thermostat and spring. Make sure that the thermostat rests on the flange before it bottoms in the thermostat housing.
2 Check the seal and sealing face and fit the plug.
Turning torque 60 Nm (44 ft. lbs.).
3 Fit the adapter housing or A/C-compressor, see.
4 Lower the car, fit the cover and check the oil level. Top up as necessary.

Reducing valve
To remove
1 Raise the car and remove the cover.





2 Unscrew the plug and extract the spring and reducing valve.

To fit





1 Fit the reducing valve and spring. Make sure that the reducing valve is an easy fit.
2 Check the seal and sealing surface and screw in the plug.
Tightening torque 25 Nm (19 ft. lbs.).
3 Fit the cover and lower the car.
4 Check the oil level and top up as necessary.

Measuring oil pressure
1 Raise the car and place a receptacle under the engine to collect the oil.





2 Remove the lower banjo screw from the oil pipe to the turbocharger by the oil filter intermediate piece and allow the engine oil to drain.
3 Connect the banjo screw on the gauge equipment, 8395576, (included in Pressure gauge equipment, fuel pressure 8393852) and tighten it. Connect the hose with pressure gauge included in the pressure gauge equipment to the outlet on the banjo screw.
4 Lower the car to the floor.
5 Position the pressure gauge so that it can be read from inside the car.

IMPORTANT: Make sure the pressure gauge hose is not resting against warm or sharp details.

6 Start the engine and read off the oil pressure. See Oil pressure.
7 Leave the engine idling to reduce the turbo speed. Turn off the engine.
8 Raise the car.
9 Remove the pressure gauge equipment.
10 Fit the oil pipe banjo screw with new seals. Wipe of any oil spill.
11 Lower the car, check the oil level and adjust as necessary.