Oil Pump Replacement and Repair

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Disassembly c. Cleaning d. Inspection e. Repair f. Assembly
                  g. Installation

Took and Special Equipment:                     References:
Shop Equipment, SC 4910-95-CL-A31               TM 9-237
Tool Kit, SC 5180-90-CL-N05
                                                Equipment Condition:
Materials/Parts:
                                                Reference                Condition Description
Bushing                P/N B-21951
                                                Page 3-220               Oil Pan Removed
Ring, Seal             P/N 23505891
                                                General Safety Instructions:
Ring, SeaI             P/N 23505892
Pin, Dowel             P/N 23505885
                                                                 WARNING
Pin, Dowel             P/N 8929011                     Sealing compounds can burn
Gasket                 P/N 23505992                    easily, can give off harmful
                                                       vapors, and are harmful to skin
Gasket                 P/N 5117269                     and clothing, To avoid injury or
Gasket                 P/N 8929347                     death, keep away from open
                                                       fire and use in well-ventilated
Nuts, Lock                                             area. If sealing compound gets
                                                       on skin or clothing, wash
Oil, Lubricating       Appendix B, Item 37             immediately with soap and
Lubriplate 105         Appendix B, Item 35             water.

TM page 3-200

Illustration from TM 9-2320-363-34-1 (PDF page 276)

1. REMOVE TWO BOLTS (1) FROM CYLINDER BLOCK (2).

2. REMOVE OIL OUTLET TUBE ELBOW (3) AND OIL OUTLET TUBE (4) FROM OIL PUMP ASSEMBLY (5).

3. REMOVE OIL OUTLET TUBE (4) FROM OIL OUTLET TUBE ELBOW (3).

4. REMOVE AND DISCARD TWO SEAL RINGS (6 AND 7).

5. REMOVE AND DISCARD GASKET (8).

6. REMOVE TWO BOLTS (9) FROM OIL OUTLET TUBE ELBOW (3).

7. REMOVE OIL PRESSURE RELIEF VALVE (10) AND GASKET (11). DISCARD GASKET.

TM page 3-201

Illustration from TM 9-2320-363-34-1 (PDF page 277)

8. REMOVE TWO LOCK NUTS (12), TWO WASHERS (13), AND TWO BOLTS (14) FROM INLET OIL TUBE BRACKET HALVES (15). DISCARD LOCK NUTS.

9. REMOVE TWO BOLTS (16) AND INLET OIL TUBE BRACKET HALVES (15) FROM CYLINDER BLOCK (2).

CAUTION

Oil pump must be adequately supported to prevent pump from dropping when retaining bolts are removed.

10. REMOVE TWO BOLTS (17), OIL INLET TUBE (18), AND GASKET (19) FROM OIL PUMP ASSEMBLY (5). DISCARD GASKET.

TM page 3-202

Illustration from TM 9-2320-363-34-1 (PDF page 278)

11. REMOVE TWO (20), Two SHORT BOLTS (21), AND OIL PUMP ASSEMBLY (5).

1. REMOVE TWO SHORT BOLTS (1) AND TWO LONG BOLTS (2) FROM OIL PUMP BODY (3).

CAUTION Be careful when removing oil pump cover to prevent damage to equipment, Oil pump driven gear and shaft assembly is retained in oil pump assembly only by cover.

2. REMOVE OIL PUMP COVER (4) AND OIL PUMP DRIVEN GEAR AND SHAFT ASSEMBLY (5) FROM OIL PUMP BODY (3).

TM page 3-203

Illustration from TM 9-2320-363-34-1 (PDF page 279)

CAUTION

Do not allow press support to interfere with oil pump drive gear and shaft assembly being pressed out. To do so will result in damage to shaft assembly.

3. PLACE OIL PUMP BODY (3), PUMP COVER SIDE DOWN, ON PRESS SUPPORT. PRESS OIL PUMP DRIVE GEAR AND SHAFT ASSEMBLY (6) FROM OIL PUMP DRIVE GEAR (7).

4. REMOVE OIL PUMP DRIVE GEAR (7) FROM OIL PUMP BODY (3).

NOTE

When one or more bushings require replacing, replace all bushings in pump body and pump cover.

5. IF BUSHINGS ARE DAMAGED OR WORN, PLACE OIL PUMP BODY (3), PUMP COVER SIDE UP, ON PRESS SUPPORT. PRESS BUSHINGS (8) FROM PUMP BODY (3).

TM page 3-204

Illustration from TM 9-2320-363-34-1 (PDF page 280)

6. PLACE OIL PUMP COVER (4), PUMP BODY SIDE UP, ON PRESS SUPPORT. PRESS OUT BUSHINGS (9) FROM HOUSING BORES (10).

TM page 3-205

Illustration from TM 9-2320-363-34-1 (PDF page 281)

CAUTION

Extreme care should be taken to protect surfaces of mounting legs from electric arc welding slag. Use fabricated protective plate for this purpose. Failure to do so could result in damage to surfaces of mounting legs.

NOTE

Two steel locating dowels (one solid diamond shaped dowel and one tubular shaped dowel) installed on pump body mounting legs are pressed in bores to specified depths. Both dowels are extremely durable and should never need to be replaced.

7. IF REMOVAL OF EITHER DOWEL (11) OR (12) IS REQUIRED, PLACE PROTECTIVE PLATE (13) ON SMOOTH SURFACE OF MOUNTING LEG (14) OVER DOWEL TO BE REMOVED. TACK-WELD WASHER (15) AND NUT (16) TO DOWEL.

NOTE

Secure pump body in soft-jawed vise with machined (smooth) surfaces of mounting legs facing up.

8. ATTACH SLIDE HAMMER (17) TO WELDED NUT ON DOWEL (11 OR 12) BEING REMOVED, AND APPLY SHORT UPWARD SHOCKING ACTIONS UNTIL DOWEL IS FREED FROM BORE. DISCARD DOWEL WITH WELDED NUT AND WASHER.

Use general cleaning methods to clean all parts (page 2-30).

1. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

2. DISCARD PUMP BODY OR PUMP COVER IF CRACKED, OR IF EVIDENCE OF SPUN BUSHINGS IN BUSHING BORES IS VISIBLE.

3. INSPECT BUSHINGS IN PUMP BODY AND COVER. SHAFT-TO-PUMP BODY BUSHING CLEARANCE WITH NEW PARTS IS 0.0016-0.0024 IN. (0.04-0.06 mm). MAXIMUM ALLOWABLE SHAFT-TO-PUMP COVER BUSHING CLEARANCE WITH USED PARTS IS 0.0035 IN. (0.089 mm).

Use general repair methods to repair damaged parts (page 2-33).

TM page 3-206

Illustration from TM 9-2320-363-34-1 (PDF page 282)

1. PLACE OIL PUMP BODY (1), COVER SIDE DOWN, ON PRESS SUPPORT.

2. APPLY THIN FILM OF LUBRIPLATE 105 TO BUSHING BORES (2).

3. POSITION BUSHINGS (3) LOOSELY OVER PUMP BODY BUSHING BORES (2).

4. ROTATE BUSHINGS (3) SO SPLIT LINES (4 AND 5) ARE PARALLEL WITH MACHINED SURFACE (6) OF PUMP BODY.

5. WHEN PROPERLY ALlNED, SPLIT LINE (4) SHOULD MEASURE 0.461 IN. (11.705 mm) TO SURFACE (6). SPLIT LINE (5) SHOULD MEASURE 1.726 IN. (43.82 mm) TO SURFACE (6).

NOTE Bushings must be installed flush to specified depth below finished surface of pump body.

6. PRESS BUSHINGS (3) IN PUMP BODY BUSHING BORES (2) NOT MORE THAN 0.031 IN. (0.8 mm) BELOW FINISHED SURFACE OF OIL PUMP BODY (1).

TM page 3-207

Illustration from TM 9-2320-363-34-1 (PDF page 283)

7. PLACE OIL PUMP COVER (7), PUMP BODY SIDE DOWN, ON PRESS SUPPORT. APPLY THIN FILM OF LUBRIPLATE 105 TO BUSHING BORES (8).

8. POSITION BUSHINGS (9) LOOSELY OVER PUMP COVER BUSHING BORES (8).

9. ROTATE BUSHINGS (9) SO SPLIT LINES (10) ARE ALINED IN PUMP COVER BUSHING BORES AS SHOWN.

NOTE

Bushings must be installed to specified depth below finished surface of pump cover.

10. PRESS BUSHINGS (9) IN PUMP COVER BUSHING BORES (8) 0.011-0.031 IN. (0.3-0.8 mm) BELOW FINISHED SURFACE OF OIL PUMP COVER (7).

TM page 3-208

Illustration from TM 9-2320-363-34-1 (PDF page 284)

PUMP COVER

PUMP BODY

NOTE Pump body and pump cover bushings are finished to size after installation in their respective bores. Use single point tooling to avoid smearing oil retention surfaces.

11. BORE OUT INSIDE DIAMETER OF BUSHINGS (3 AND 9) IN OIL PUMP BODY (1) AND OIL PUMP COVER (7) TO 0.879-0.880 IN. (22.32-22.35 mm).

TM page 3-209

Illustration from TM 9-2320-363-34-1 (PDF page 285)

12. INSTALL ROUND DOWEL (11) IN BORE OF PUMP BODY MOUNTING SURFACE (12). TOP OF ROUND DOWEL (11) SHOULD BE 0.197 IN. (5.0 mm) FROM MOUNTING SURFACE (12) WHEN PROPERLY SEATED IN BORE.

NOTE

Diamond dowel must be oriented in relation to round dowel before installing in pump body mounting surface.

13. LOOSELY PLACE DIAMOND DOWEL (13) IN BORE OF PUMP BODY MOUNTING SURFACE (12) SO ANGULAR ORIENTATION IS PERPENDICULAR TO CENTER LINE THROUGH ROUND DOWEL (11) WITHIN 5 DEGREES.

14. INSTALL DIAMOND DOWEL (13) IN BORE OF PUMP BODY MOUNTING SURFACE (12). TOP OF DIAMOND DOWEL (13) SHOULD BE 0.307-0,323 IN. (7.8-8.2 mm) ABOVE SURFACE (12) WHEN PROPERLY SEATED IN BORE.

TM page 3-210

Illustration from TM 9-2320-363-34-1 (PDF page 286)

15. PLACE OIL PUMP BODY (1), WITH COVER SIDE DOWN, ON PRESS SUPPORT. LUBRICATE TWO BUSHINGS (3) WITH CLEAN ENGINE LUBRICATING OIL.

16. APPLY THIN FILM OF LUBRIPLATE 105 TO BORE OF OIL PUMP DRIVE GEAR (14).

17. INSTALL LONGER END OF INTERNAL OIL PUMP DRIVE GEAR (14) AND SHAFT ASSEMBLY (15) IN RIGHT SIDE BUSHING AS VIEWED FROM TOP REAR.

CAUTION Minimum press force of 1,515 lb. (7.0 kN) must be obtained to press oil pump drive gear onto oil pump drive gear and shaft assembly to prevent damage to equipment. Balance holes in drive gear rim must face pump body to avoid possibility of installing drive gear backwards.

18. PLACE END OF INTERNAL OIL PUMP DRIVE GEAR (14) AND SHAFT ASSEMBLY (15) ON PRESS SUPPORT, PRESS OIL PUMP DRIVE GEAR (14) ON GEAR AND SHAFT ASSEMBLY (15), USING FEELER GAGE, ENSURE THAT CLEARANCE OF 0.033-0.044 IN. (0.85-1.15 mm) IS OBTAINED BETWEEN OIL PUMP DRIVE GEAR (14) AND OIL PUMP BODY (1).

TM page 3-211

Illustration from TM 9-2320-363-34-1 (PDF page 287)

19. INSTALL SHORTER END OF OIL PUMP DRIVEN GEAR AND SHAFT ASSEMBLY (16) IN LEFT SIDE BUSHING IN OIL PUMP BODY (1) AS VIEWED FROM TOP REAR.

20. LUBRICATE BUSHINGS (3) IN OIL PUMP COVER (7) WITH LIGHT ENGINE LUBRICATING OIL.

21. INSTALL OIL PUMP COVER (7) ON OIL PUMP BODY (1).

22. INSTALL TWO SHORTER BOLTS (17) IN UPPER TWO BOLTS HOLES AND TWO LONGER BOLTS (18) IN LOWER TWO BOLT HOLES IN OIL PUMP COVER (7). TIGHTEN BOLTS TO 22-28 LB-FT (30-38 N.m) IN CRISSCROSS PATTERN.

23. MOUNT DIAL INDICATOR ON MACHINED SURFACE OF RIGHT SIDE OIL PUMP BODY MOUNTING LEG OR OTHER SUITABLE CLAMPING SURFACE.

24. MEASURE GEAR FACE RUNOUT JUST INBOARD OF OIL PUMP DRIVE GEAR TEETH (19) WHILE ROTATING GEAR BY HAND. GEAR FACE RUNOUT MUST NOT EXCEED 0.003 IN. (0.007 mm). IF GEAR FACE RUNOUT EXCEEDS 0.003 IN. (0.007 mm), REPLACE GEAR.

TM page 3-212

Illustration from TM 9-2320-363-34-1 (PDF page 288)

1. POSITION OIL PUMP ASSEMBLY (1) ON CYLINDER BLOCK (2) WITH OIL PUMP DRIVE GEAR (3) ENGAGED WITH CRANKSHAFT GEAR (4). MAKE SURE RING DOWEL AND DIAMOND DOWEL ARE FULLY SEATED IN CYLINDER BLOCK (2).

2. INSTALL TWO LONGER BOLTS (5) IN FRONT BOLT HOLES AND TWO SHORTER BOLTS (6) IN REAR BOLT HOLES IN OIL PUMP ASSEMBLY (1). TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m) IN CRISSCROSS PATTERN.

TM page 3-213

Illustration from TM 9-2320-363-34-1 (PDF page 289)

CAUTION Do not interchange oil pressure regulator valve and oil pressure relief valve to prevent damage to equipment, Oil pressure regulator valve port opening is larger than oil pressure relief valve port opening. Oil pressure regulator valve is also identified by pin located farthest from outlet port. **NOTE**

Make sure all old gasket material has been removed from mating surfaces of oil pressure relief valve and elbow.

3. INSTALL NEW GASKET (7) AND OIL PRESSURE RELIEF VALVE (8) ON OIL OUTLET TUBE ELBOW (9). INSTALL TWO BOLTS (10) AND TIGHTEN TO 22-24LB-FT (30-38 N.m).

4. COAT TWO NEW SEAL RINGS (11 AND 12) WITH LIGHT ENGINE LUBRICATING OIL. INSTALL SMALLER SEAL RING ON ELBOW END OF OIL OUTLET TUBE (13) AND LARGER SEAL RING ON PUMP END OF OIL OUTLET TUBE (13).

5. INSTALL LARGER DIAMETER END OF OIL OUTLET TUBE (13) IN OUTLET NECK OF OIL PUMP ASSEMBLY (1) UNTIL OIL OUTLET TUBE (13) BOTTOMS IN BORE.

6. INSTALL SMALLER DIAMETER END OF OIL OUTLET TUBE (13) IN OIL OUTLET TUBE ELBOW (14) UNTIL OIL OUTLET TUBE (13) BOTTOMS IN BORE.

NOTE

Make sure all old gasket material has been removed from mating surfaces of oil outlet tube elbow and cylinder block.

7. INSTALL NEW GASKET (15) AND OIL OUTLET TUBE ELBOW ASSEMBLY (14) ON CYLINDER BLOCK (2). INSTALL TWO BOLTS (16) AND TIGHTEN TO 22-24 LB-FT (30-38 N.m).

TM page 3-214

Illustration from TM 9-2320-363-34-1 (PDF page 290)

8. INSTALL NEW GASKET (17) AND OIL INLET TUBE (18) ON OIL PUMP ASSEMBLY (1). INSTALL TWO BOLTS (19) AND TIGHTEN TO 22-24 LB-FT (30-38 N.m).

9. INSTALL TWO OIL INLET TUBE BRACKET HALVES (20) AND TWO BOLTS (21) ON CYLINDER BLOCK (2), TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m).

10. INSTALL TWO BOLTS (22), TWO WASHERS (23), AND TWO NEW LOCK NUTS (24) ON OIL INLET TUBE BRACKET HALVES (20). TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m).

TM page 3-215

Illustration from TM 9-2320-363-34-1 (PDF page 291)

NOTE Gear lash measurements between crankshaft gear and oil pump drive gear must be taken with engine in running position. Remove or install shims as necessary to obtain proper lash.

11. WITH DIAL INDICATOR TIP RESTING ON TOOTH OF OIL PUMP DRIVE GEAR (3), MEASURE GEAR LASH BETWEEN OIL PUMP DRIVE GEAR AND CRANKSHAFT DRIVE GEAR (4). GEAR LASH SHOULD BE 0.002-0.009 IN. (0.051-0.229 mm).

12. IF GEAR TOOTH CLEARANCE IS NOT WITHIN SPECIFICATIONS, REPEAT REMOVAL STEPS 1 THRU 10.

13. INSTALL REQUIRED AMOUNT OF SHIMS (25) BETWEEN OIL PUMP ASSEMBLY (1) AND CYLINDER BLOCK (2).

14. REPEAT INSTALLATION STEPS 1 THRU 10.

15. VERIFY GEAR LASH. REPEAT STEP 11.

NOTE Follow-on Maintenance:

Install oil pan (page 3-220).

TM page 3-216

Illustration from TM 9-2320-363-34-1 (PDF page 292)