Intermediate shaft driven pump
Removal
1. Remove the pan as described in Chapter 13 or 14, depending on the model.
2. Unscrew the four bolts securing the end of the pump housing and remove the pump from the crankcase (see illustration).
15.2. Remove the oil pump from the crankcase.
Inspection
3. Unscrew the mounting bolts and remove the pump cover.
4. Remove the idler gear and pinion gear/shaft (see illustration).
15.4. Oil pump.
Mark the idler gear so that it can be installed in the same position.
5. Remove the retaining clip and remove the spring retainer, spring, support and plunger of the pressure reducing oil valve.
6. Clean the components and carefully inspect the gears, pump body and relief valve plunger for scoring and signs of wear. Replace the pump if excessive wear is present.
7. If the components are serviceable, measure the clearance between the pump body and the gears using a feeler gauge. Also measure the axial clearance of the gears and check the flatness of the end cover (see illustrations).
15.7a. Locations for measuring clearances (A) between gears and the oil pump housing.
15.7b. Check the clearance between the oil pump gears and the housing.
15.7s. Locations for measuring the axial clearance of the oil pump gears (B).
15.7d. Check the axial clearance of the oil pump gears.
15.7e. Check the flatness of the oil pump cover.
If the gaps exceed those specified in Specifications permissible deviations, the pump must be replaced. Fill the pump with oil, then install the cover and tighten the bolts securely (see illustration).
15.8. Tighten the oil pump cover bolts.
Make sure the alignment pin is in the operating position where the drive shaft enters the oil pump housing.
Installation
8. If the pump is OK, reassemble it in reverse order.
9. Wipe the mating surfaces of the oil pump and crankcase.
10. Place the oil pump in the crankcase, engaging the shaft with the drive gear. Insert and fully tighten the mounting bolts (see illustration).
15.10. Tighten the oil pump mounting bolts.
11. Install the tray as described in Chapter 13 or 14, depending on the model.
Chain driven oil pump
Removal
12. Remove the pan as described in Chapter 13 or 14, depending on the model.
13. Remove the two bolts securing the oil pump to the crankcase, then tilt it to disengage it from the drive chain and remove it from the engine (see illustration).
15.13. Oil pump mounting bolts (marked with arrows) - chain driven.
Inspection
14. Proceed as described in points 3-8.
Installation
15. Wipe the mating surfaces of the oil pump and crankcase.
16. Make sure the locating pins are in the working position, then position the oil pump in the crankcase, tilting it to engage the drive chain with the sprocket, then insert and tighten the mounting bolts.
17. Install the tray as described in Chapter 13 or 14, depending on the model.
Drive chain and sprockets
Removal
18. Remove the pan as described in Chapter 13 or 14, depending on the model.
19. Remove the toothed drive belt as described in Chapter 5 or 6, depending on the model.
20. Remove the crankshaft sprocket and idler pulley as described in Chapter 7.
21. If not already done, remove the woodruff key from the slot on the end of the crankshaft, then unscrew the lower rear drive cover from the cylinder block.
22. Unscrew the bolts and remove the front plate from the cylinder block, marking the mounting pins. Where applicable, remove the spacer shim from the crankshaft.
23. Remove the oil pump drive chain guide block from the mounting pins.
24. Remove the bolts securing the sprocket to the oil pump hub. To hold the sprocket, insert a screwdriver through one of the holes in it.
25. Remove the drive sprocket from the crankshaft and the driven sprocket from the oil pump hub, and remove both sprockets together with the chain. It is very important to tighten the crankshaft pulley bolt correctly, otherwise the oil pump will not function.
Inspection
26. Inspect the drive chain. Chain wear can be assessed by holding the chain horizontally and observing the deflection.
27. Inspect the teeth on the sprockets. If the teeth are "hooked", replace the sprockets. It is recommended to replace sprockets and chain as a matched set, as older components will wear out faster.
28. Inspect the chain guide block for signs of wear and replace it if necessary.
Installation
29. Place the chains on the sprockets, then install both sprockets with the chain on the crankshaft and on the oil pump hub.
30. Align the holes, then insert the driven sprocket bolts and tighten them securely while holding the sprocket with a screwdriver.
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31. The oil seal should be replaced every time the front plate is removed as described in Chapter 16.
32. If not already done, scrape off all traces of sealant from the plate and cylinder block.