Installation

Replacement of Oil Pump

To Fit

NOTE:
^ Step numbers below refer to numbers used in the illustrations.
^ In vehicle.




1. Position the impellers in the pump housing and install the cover.
On reassembly, note that the marking on the impellers should face outwards.
2. Position a new gasket and install the pump housing, then tighten to: 6 Nm (4.5 ft. lbs.).





3. Install the bracket and engine mounting, then tighten to: 47 Nm (35 ft. lbs.).
4. Raise the car and remove the stand.
5. Install the cable for the oil pressure switch.
6. Install the antislosh baffles, oil strainer and oil pan.
- Apply Loctite 242, or equivalent, to secure the bolts and tighten as follows:
- Antislosh baffles: 8 Nm (6 ft. lbs.).
- Oil suction pipe: 8 Nm (6 ft. lbs.).
- Oil pan: 15 Nm (11 ft. lbs.).
7. Install the A/C compressor.
8. Install the alternator.





9. Install the subframe, then tighten mounting bolts as follows:
- Front: 115 Nm (85 ft. lbs.).
- Centre: 190 Nm (140.6 ft. lbs.).
- Rear: 110 Nm plus an additional 75° (81.4 ft. lbs. plus an additional 75°).
10. Install the crankshaft pulley and tighten to: 250 Nm Plus an additional 45° (184.5 ft. lbs. plus an additional 45).
11. Remove the flywheel stop and install the protective plate.
12. Install the spoiler sections and the front exhaust pipe.
13. Lower the car to the floor.
- Remove the lifting sling and yoke.
14. Install the timing cover retaining bolts.
- Use an open-ended wrench to rotate camshaft sprocket No. 1 so that the timing cover retaining bolt behind the sprocket can be fitted.
- Exercise care so that the camshaft does not "snap".
- Turn the camshaft sprocket back to the zero position.
- Do the same with camshaft sprocket No. 2.





15. Install the bracket for the tensioning roller and the middle adjusting roller.
16. Install locking tool No. 83 94 926, or equivalent, on No. 1 and No. 2 camshaft sprockets and also on No. 3 and No. 4 camshaft sprockets.
17. Turn the crankshaft to 0° and install locking tool onto it.
18. Install the toothed belt according to its marked direction of rotation and markings (camshafts and crankshaft).
- Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs.
- Always adjust counterclockwise.
- Install a length of the toothed belt in place and install measuring tool No. 83 93 985 to measure the belt tension.
- Tighten the centre bolts of the adjusting roller lightly.
- Adjust the adjusting rollers counterciockwise
- Begin with the lower one and adjust it to a belt tension of 275-300 Nm (203-221 ft. lbs.).

Note: this adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

19. Then carry out adjustment by means of the tensioning roller, mark against mark.
- Remove the locking tool for camshaft sprockets 1 and 2.
- Carry out final adjustment with the upper middle adjusting roller until camshaft sprocket No. 2 moves 1-2 mm forwards.
- Remove the locking tools for camshaft sprockets 3 and 4 and also the crankshaft locking tool.
20 Turn the engine over two revolutions to the zero mark and install the locking tool on the crankshaft.
- Check that the markings on the camshaft sprockets are in alignment with the markings on the timing cover.
- Check this by positioning the two locking tools, which should install, and also by fitting a locking tool on camshaft sprockets 1 and 2 and 3 and 4.

NOTE:
^ Also check the tensioning roller to ensure that the marks are in alignment, then tighten as foll0ws:
- Tensioning roller: 20 Nm (15 ft. lbs.).
- Upper adjusting roller: 40 Nm (30 ft. lbs.).
- Lower adjusting roller: 20 Nm (15 ft. lbs.).

21. Install the crankshaft pulley and tighten to: 20 Nm (15 ft. lbs.).
22. Install the cover, water pump pulley, power steering pump pulley, belt tensioner and multigroove drive belt.
- Install the power steering pump.





23. Install the right-hand front wheel and the cover in the wheel housing, tighten wheel bolts to: 120 Nm (89 ft. lbs.).
24. Install the air cleaner and mass air flow sensor.
25. Reconnect the negative cable to the battery.
- Change the engine oil and oil filter.
- Check all oil and fluid levels and top up as necessary.
- Check that the engine bay is clean.
- Remove the protective covers on the fenders.
26. Start the engine and check all functions.
- Test drive the car.