1. Remove the timing belt and crankshaft sprocket as described in Chapter 40.
2. Remove the sump as described in Chapter 42.
3. Remove the dipstick to measure the oil level.
4. Remove the two bolts securing the oil suction tube to the crankcase (photo). Knock back the tabs on the stop plate on the suction tube flange (photo), remove the bolts and suction tube.
5. Unscrew the bolts securing the oil pump, remove the oil pump and gasket (photo).
6. Loosen the screws securing the pump shield, lift the shield (photo).
7. Check that there are marks on the visible surface of the gears. If not, make a mark so as not to confuse which side of the gears were facing the engine before removal.
8. Unscrew the pressure relief valve, remove the plug, O-ring, spring and plunger (photo).
9. Clean all parts, check the condition of the pump body and shield, pressure relief valve plunger and bearing surface, check that the spring is not damaged or distorted. Check the condition of the gears. New gears can be used, but they must be installed in pairs.
10. Remove the stuffing box from the front of the pump. Lubricate the protrusion of the new oil seal, insert the seal with the closed surface outward, hammer the bar into place. If there is a groove on the crankshaft in the area where the seal lug rubs, the seal can be pushed to the bottom of the notch so that the lug passes over to the undamaged part of the crankshaft.
11. Assemble the pump by installing the gears and shield. The inner gear is located with the splined end towards the crankshaft, although the outer gear can be installed either way, it is recommended to install it as it was before removal. Some gears have a triangle, this mark must be facing forward.
12. Install the oil pump with a new gasket, make sure that the lug on the crankshaft fits into the groove on the inner gear.
13. Insert and tighten the bolts in a diagonal sequence with the tightening torque specified specification.
14. Install the oil suction tube with a new gasket, tighten the bolts, bend the lock plate keys onto the flange bolts.
15. Install the dipstick, sump (Chapter 42), toothed belt drive and crankshaft sprocket (Chapter 40).
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