Oil pump (page 5 of 5)

Refit

1. Clean all traces of gasket and sealing materials from engine and gearbox mating faces.
2. Clean locating dowels.
3. Lubricate with clean engine oil and fit new ’O’ ring and main bearing cap oil seal to gearbox.
4. Fit gaskets to face of gearbox.
5. Move primary drive gear to end of crankshaft.
6. Lower engine onto gearbox.
7. Fit nuts and bolts securing gearbox to engine and tighten to 8 Nm.
8. Fit nut and bolt securing engine to gearbox and tighten to 8 Nm.
9. Position primary drive gear into mesh.
10. Remove all traces of gasket material from mating face of flywheel housing, engine and gearbox.
11. Clean flywheel housing locating dowels.
12. Position flywheel housing on a flat surface and support underside adjacent to seal aperture.
13. Clean oil seal aperture in flywheel housing.
14. Lubricate new flywheel housing oil seal.

15. Position oil seal to flywheel housing and using tools 18G 134 and 18G 134BC drift oil seal into place.
16. Fit new gasket to engine and gearbox.
17. Ensure protective sleeve is fitted to primary gear splines and locate flywheel housing on dowels.
18. Clean Loctite from threads of flywheel housing bolts with a wire brush.
19. Apply Loctite 242 to first 3 threads of each bolt.
20. Fit 8 inner bolts securing flywheel housing to engine and gearbox and tighten to 25 Nm.

NOTE: Ensure 3 bolts with the finer thread are fitted at the top.

21. Position bracket to housing, fit lower bolts securing housing to gearbox and tighten to 25 Nm.
22. Fit upper bolts securing flywheel housing to engine and tighten to 25 Nm.
23. Remove protective sleeve 18G 1043 from primary gear splines.
24. Clean crankshaft taper and flywheel.
25. Fit dust shield on primary gear.
26. Fit flywheel and clutch assembly to crankshaft.
27. Fit key plate and NEW flywheel retaining bolt.
28. Tighten flywheel retaining bolt to 150 Nm.
29. Stake lock washer into slots on clutch hub.
30. Remove bolts securing flywheel locking tool.
31. Remove flywheel locking tool.
32. Clean thrust bearing sleeve.
33. Fit thrust bearing sleeve to clutch hub.
34. Clean CKP sensor and mating face of flywheel housing.
35. Fit CKP sensor to flywheel housing, fit bolts and tighten to 6 Nm.
36. Clean flywheel housing cover and mating face of flywheel housing.
37. Position cover to flywheel housing, fit bolts and tighten to 10 Nm.
38. Fit clutch slave cylinder mounting bracket and spacer to flywheel housing.
39. Fit 3 bolts securing mounting bracket to flywheel housing, tighten bolts: M8 bolts to 37 Nm. M5 bolt to 7 Nm.
40. Clean mating face of starter motor and flywheel housing.
41. Fit starter motor and tighten bolts to 37 Nm.
42. Fit engine and gearbox. See this section.