1. Remove the oil pump from the car (see «Removal and installation of the oil pump»).
2. Key «on 10» Remove the crankshaft position sensor bolt..
3.... and remove the sensor.
4. Hex key «by 5» remove the six bolts securing the pump cover.
5. Using two screwdrivers, pry up the pump casing until the dowel pins on the cover come out of the holes in the casing and remove the pump casing from the cover.
6. Remove the drive from the housing...
7.... and pump driven gear.
8. Hex key «for 8» unscrew the plug of the pressure reducing valve. Please note that an aluminum sealing ring is installed under the plug. Replace heavily compressed ring.
9. Remove pressure reducing valve spring.
10. Remove the relief valve by carefully tapping the cap on a clean piece of wood. If the valve does not come out, remove it with a pointed wooden stick.
11. Examine the cover. In the contact area of the gears, it should not have noticeable signs of wear, scoring and deep scratches. Otherwise, replace the cover.
12. Inspect the pump housing. On its working surfaces there should be no noticeable signs of wear, scoring and deep scratches. Otherwise, replace the body.
13. Measure the diameter of the driven gear seat in the pump housing. The maximum allowable diameter is 75.1 mm. If the size is larger than specified, replace the housing.
14. Measure the width of the pump casing segment at the middle. If the width is less than 3.4 mm, replace the case.
15. Measure the thickness of the drive gear. If it is less than 7.42 mm, replace the gear.
16. Measure the thickness of the driven gear. If it is less than 7.35 mm, replace the gear.
17. Check up axial backlashes of gear wheels. To do this, install the drive gear in the cover, put a metal ruler on the cover and measure the gap between the ruler and the gear with a feeler gauge.
18. In the same way, measure the axial clearance of the driven gear. The maximum allowable axial clearance of the drive gear is 0.12 mm, the driven gear is 0.15 mm. If clearances are greater than specified, replace gears.
19. More precisely, the axial clearances of the gears can be obtained by calculation. To do this, measure the thickness of the housing along the outer surfaces with a micrometer...
20.... and the thickness of the cover in the area of the socket for the gears in several places (on milled surfaces). Calculate the axial clearance as the difference between the arithmetic mean of the socket depth and the thickness of the gears.
21. Inspect the relief valve seat. There should be no burrs or deep scratches on its inner surface. Otherwise, replace the body.
22. Replace pressure reducing valve if it has scores or deep scratches.
23. Replace bent, broken, or cracked relief valve spring. The height of the spring in the free state should be 44.72 mm, under load (4±0,24) kgf - 31.7 mm. Otherwise, replace the spring.
24. Install the driven gear into the pump housing. The chamfers on the gear teeth must face the housing.
25. Install the drive gear into the pump housing. The chamfers on the gear teeth must face the housing.
26. Install the housing on the cover and screw in the mounting bolts.
27. Lubricate the pressure reducing valve with engine oil and install it in the socket with the bottom down. Then install the spring and wrap the plug with the o-ring.
28. Fill the pump with engine oil through the oil receiver hole.
29. Rotate the pump gears a few turns to lubricate their running surfaces.