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.
Removal
Removing the engine components
Warning! Ensure that the no servo oil overflows from the servo and expansion tanks. Extremely flammable.
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 them up and place them on top of the engine
- the auxiliaries belt
- the front timing belt cover.
Engine adjustment according the markings
Raise the vehicle. See: Jacking points, body Service and Repair.
Remove the right-hand front wheel.
Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
Turn a further 1/4 turn clockwise and then back counter-clockwise until the markings correspond.
Remove the upper camshaft cover.
Removing timing belt
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw in place. Turn the tensioner eccentric clockwise to 10 o'clock. Use a 6 mm Allen key.
Remove the timing belt.
Removing 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.
Removing the crankshaft pulley
Use: 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.
Caution! Ensure that the tool claws do not damage the pulley teeth.
Install the puller so that the claws engage in the screws, not in the camshaft pulley.
When only replacing the front crankshaft seal
Caution! Ensure that the crankshaft does not rotate when pressing in the 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.
Removing the oil pump
Remove:
- the 4 x oil pump screws
- the oil pump. Carefully break at the stop lugs. Use a groove-cut chisel.
Clean the gasket face and the mating surfaces.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Installing the oil pump
Install:
- a new oil pump
- a new gasket.
Caution! Ensure that the sealing ring in the oil pump is not damaged during installation
Carefully insert the oil pump over the end of the crankshaft.
Install 4 x new screws as guides.
Note! Ensure that the crankshaft does not rotate when drawing in the pump.
Pull in the oil pump with drift: 999 5455 PUNCH 999 5455 Punch and the crankshaft center nut.
Tighten the screws alternately.
Note! The timing gear pulley can only be in one position on the splines on the end of the crankshaft.
Install the crankshaft timing gear pulley.
Carefully tap alternately around the pulley until end position is reached.
Installing the vibration damper
Install the vibration damper.
Tighten the center nut. See: Tightening torque Tightening Torque.
Use: 999 5433 COUNTERHOLD 999 5433 Counterhold.
Remove the counterhold. Tighten and angle-tighten the screws. Use protractor: 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Installing 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.
Installing the timing belt
This adjustment is to be made with a cold engine. 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.
Turn the crankshaft carefully clockwise until the timing belt is in tensioned positioned (tensioned between 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. Tighten the center screw. See: Tightening torque Tightening Torque. Ensure that the indicator is in the correct position.
Press the belt to see that the indicator on the tensioner moves easily.
Install 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:
- the front camshaft cover
- the upper camshaft 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 on the suspension turret.
Check the function
Check the oil level. Top up as necessary.
Start the engine.
Check that there is no oil leakage.
Stop the engine and give the oil time to run down into the oil pan.
Then check the oil level.
Top up if necessary.
Wipe the engine compartment clean.
Ensure that the steering wheel and the gear selector lever are clean.