Removal
1. Disconnect the negative cable from the battery.
Caution: If your vehicle has a theft-protected audio system, make sure you have the unlock code before disconnecting the battery.
2. Remove the mudguard from under the engine. Remove the accessory drive belts (see chapter 1).
3. Remove the generator (see chapter 5) Remove the air conditioning compressor (without disconnecting the hoses from it) and secure it somewhere to the side.
[Based on website data www.mazbook.ru]
4. Remove the timing belt and crankshaft sprocket (see paragraph 6).
5. Remove the oil pan (see paragraph 12). Remove the oil intake pipe (figure 13.5).
6. Loosen the bolts in the opposite order to that shown in the figure 13.23, unscrew them and remove the lower crankcase reinforcement.
Note: On engines produced since 1998, the bolt pattern on the transmission side is slightly different.
7. Loosen the bolts securing the oil pump to the cylinder block and remove the pump (Fig. 13.7). If necessary, gently pry the pump housing away from the block with a small screwdriver.
Examination
8. Place the pump on the workbench. Remember to what depth the cuff is pressed into the pump body. Pull the cuff out of the socket (do not damage the bore under the cuff).
9. Remove the screws connecting the cover to the pump body. Remove and inspect the cover for damage or warping.
10. Unscrew the pressure reducing valve. Remember which side the valve parts are inserted into the bore. Remove the pump gears, wash them in solvent and reinstall them.
11. Measure the following gaps with feeler gauges and compare them with the values specified in Technical data.
- a) Between the driven gear and the pump body (figure 13.11,a)
- b) Between the projections of the teeth of the driving and driven gears (figure 13.11,b)
- c) Between the ends of the gears and the plane of the cover (figure 13.11,c)
12. Measure the length of the pressure reducing valve spring in its free state. Compare the result with the value specified in Technical data. Replace the spring if necessary.
13. Clean and rinse the pump parts before assembly.
14. Remove the outer surface of the new seal with clean engine oil. Press the cuff into the socket with a hammer through a mandrel with an outer diameter slightly smaller than the outer diameter of the cuff (for this purpose, you can use a piece of pipe or a socket head of a suitable size). Press the cuff to the same depth as before disassembly. Wet the working edge of the cuff with oil, which contacts the nose of the crankshaft.
15. Dip the plunger of the pressure relief valve into oil and assemble the valve. Secure the valve plug with a snap ring.
16. Dip the pump gears in oil and insert them into place.
17. Fill the pump cavities with technical petroleum jelly (this will help the pump start pumping oil immediately after the engine starts).
18. Install the pump cover, apply a compound to the threads of the cover mounting screws to prevent them from loosening. Insert and tighten the screws securely.
19. Inspect the oil intake pipe and filter mesh to ensure they are not clogged with dirt. Flush the pipe and mesh, or replace the entire assembly.
Installation
20. Scrape off any remaining old gasket and sealant from the cylinder block mounting surface. Wash the mating surfaces of the pump and block with nitro solvent or acetone.
21. Apply a thin layer of sealant to the pump mounting surface and place a new gasket on it. Reinstall the pump. If necessary, rotate its gears to engage them with the shaft nose. Be careful when applying the sealant so that it does not get into the pump channels.
22. Screw in the bolts and tighten them to the specified torque.
23. Wipe the lower surface of the cylinder block and the mating surface of the booster. Apply a bead of RTV sealant around the perimeter of the booster mounting surface and around the four booster-to-rear main bearing cap bolt holes. Install the amplifier within 5 minutes after applying the sealant. Gradually, in three to four passes, tighten the amplifier mounting bolts to the required value in the sequence shown in the figure 13.23.
24. The rest of the assembly is carried out in the reverse order of disassembly.