820518A93 Force DECAL SET (Complete) (BAYLINER)

1. Drain the coolant from the cooling system. 2. Remove bolts (1), (2) and (4) and adapter (3). 3. Remove four bolts (8). Remove elbow (5) and tube (6).4. Remove the flange and tube (7) from the oil cooler bonnet. 5. Using tool (A), attach a hoist to oil pump (9).6. Remove bolt (10) and (11). Remove wiring harness clip (12). Remove oil pump (9). The weight of the oil pump is 39 kg (85 lb). The following steps are for the installation of the oil pump.7. Put clean engine oil on the O-ring seals. Using tool (A) and a hoist, install oil pump (9). Make sure the splines on the pump shaft are correctly engaged with the splines of the oil pump drive. Install bolts (10) and (11).8. Put clean engine oil on the O-ring seals and install tube (6) in the bypass elbow. Install elbow (5) on tube (6) with the bolts.9. Put clean engine oil on the O-ring seals and install tube (7) and the flange as a unit in the oil cooler bonnet.10. Install gaskets and adapter (3) with bolts (1), (2) and (4).11. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Oil Pump
Start By:a. remove oil pump
Cover (2) has spring tension under it. To prevent personal injury, loosen bolts (1) slowly and equally to remove the tension under the cover.
1. Remove bolts (1), cover (2), gasket (3), spring (4) and valve spool (5). 2. Remove cover assembly (6) and the gasket. 3. Remove cover assembly (7). 4. Using tooling (A), remove bearings (8) from cover assembly (7). 5. Remove shaft assemblies (10) from body assembly (9). 6. Using a press, remove gears (11). 7. Use tooling (A) to remove bearings (12) from body assembly (9).Assemble Oil Pump
1. Align bearings (12) so that the joints are 45° 15° from a line through the center of the bearing bores as shown.2. Using tooling (A), install bearings (12) in the body assembly until they are 1.5 0.5 mm (.06 .02 in) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in). 3. Heat gears (11) to a maximum temperature of 316°C (600°F).4. Install gears (11) on two idler shaft assemblies (10) until they are 64.0 0.5 mm (2.52 .02 in) from the body end of the shaft assemblies to the face of the gears.5. Install gear (11) on drive shaft assembly (13) until it is 47.0 0.5 mm (1.85 .02 in) from the cover end of the shaft assembly to the face of the gear. 6. Install shaft assemblies (10) and (13) in body assembly (9). 7. Make sure dowels (14) and (15) are installed in cover assembly (7) so they extend 6.0 0.5 mm (.24 .02 in) above the surface of the cover assembly.8. Using tooling (A), install bearings (8) in cover assembly (7) with the joints of the bearings positioned as shown. 9. Install cover assembly (7) and tighten the bolts. 10. Make sure the two pins in cover assembly (6) are installed so they extend 6.0 1.0 mm (.24 .04 in) above the surface of the cover assembly. Install the gasket and cover assembly (6). 11. Put clean engine oil on valve spool (5). Install valve spool (5), spring (4), gasket (3), cover (2) and the bolts.End By:a. install oil pump