Removal
1. Drain the engine oil (see the relevant section), then install a new sealing washer and tighten the drain plug to the specified tightening torque Specifications. Remove the oil filter - it needs to be replaced.
2. Remove the toothed drive belt (see Chapter 7).
3. Remove the inner timing belt cover as described in Chapter 6.
4. Remove the oil pan and the pump strainer (see Chapter 12).
5. Disconnect the electrical connector from the oil pressure sensor.
6. Loosen and remove the mounting bolts, then pull the oil pump housing assembly off the end of the crankshaft, being careful not to lose the mounting pins. Remove the housing gasket - it must be replaced.
Bulkhead
7. Loosen the mounting screws and remove the pump cover from the rear of the casing (see illustration).
8. Mark the top side of both pump gears with a marker to ensure they are installed correctly.
9. Remove the inner and outer gears from the pump housing (see illustration).
10. Unscrew the oil pressure relief valve bolt from the front wall of the casing and remove the spring and plunger from the casing, remembering the correct location of the latter (see illustration). Remove the sealing washer from the valve bolt.
Caution! The bypass valve can be removed from the pump without removing the pump from the engine. On models with air conditioning, this will require unscrewing the compressor bracket assembly bolts.
11. Clean the components and carefully inspect the gears, pump housing and relief valve plunger for scoring and wear. Replace any worn or damaged components. If the gears or pump housing are scratched, the entire pump assembly must be replaced.
12. If the components appear to be serviceable, measure the clearance between the inner and outer gears with a feeler gauge. Also measure the axial clearance of the gears and check the pump cover for distortion (see illustrations). If the gaps exceed those specified in Specifications values, replace the pump.
13. If the pump condition is satisfactory, reassemble the components in the reverse order of removal, paying attention to the following:
- a) Orient the gears according to the marks made before removal.
- b) Install a new O-ring on the bypass valve bolt and tighten the bolt to the specified tightening torque Specifications.
- c) Tighten the pump cover screws with the specified tightening torque Specifications.
- d) Finally, prime the oil pump with clean engine oil by rotating the internal gear.
Installation
14. Before installation, carefully pry the crankshaft oil seal out using a flat-head screwdriver. Orient the new oil seal with the sealing lip inward, lubricate the lip with clean engine oil and push the oil seal into the housing using a tubular drift. The tool should rest only on the hard outer edge of the seal (see illustration). The seal should be flush with the casing.
15. Make sure the contact surfaces of the oil pump and cylinder block are clean and dry and place the dowel pins in the operating position.
16. Install a new gasket on the cylinder block.
17. Carefully move the oil pump into the working position and fit the internal gear onto the end of the crankshaft. Install the pump on the pins, being careful not to damage the sealing edge of the oil seal.
18. Install the pump casing mounting bolts each strictly in their original place and tighten them with the specified tightening force Specifications.
19. Connect the oil pressure sensor wiring connector.
20. Install the oil pump suction tube/strainer and pan (see Chapter 12).
21. Install the inner timing belt cover and tighten the mounting bolts to the specified tightening torque Specifications.
22. Install the sprockets, idler pulleys and timing belt tensioner, then install the belt (see Chapters 7 and 8).
23. Finally, install a new oil filter and fill the engine with clean oil as described in Section 1.
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