Avalanche, Express, Savana 2006-2007

Oil Pump

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Inspection



4.3L Engine

CAUTION
Wear safety glasses in order to avoid eye damage.



Click image to see an enlarged view

Fig. Exploded view of the oil pump-4.3L engines

  1. Clean the oil pump components in cleaning solvent.
  2.  
  3. Dry the components with compressed air.
  4.  
  5. Inspect the oil pump for the following conditions:

    Scoring on the top of the gears (1)
     
    Damaged gears (2) for the following:
     
    Chipping
     
    Galling
     
    Wear
     
    Scoring, damage or casting imperfections to the body (3)
     
    Damaged or scored gear shaft (4)
     
    Damaged or scored gear shaft (5)
     
    Damaged bolt hole threads
     
    Worn oil pump driveshaft bore
     
    Damaged or sticking oil pump pressure relief valve Minor imperfections may be removed with a fine oil stone.
     
    Collapsed or broken oil pump pressure relief valve spring
     
    If the oil pump is to be reused, install a NEW oil pump pressure relief valve spring.
     
    During oil pump installation, install a NEW oil pump driveshaft retainer.
     

  6.  

4.8L, 5.3L & 6.0L Engines

CAUTION
Wear safety glasses in order to avoid eye damage.



Click image to see an enlarged view

Fig. Exploded view of oil pump-4.8L, 5.3L and 6.0L engines


NOTE
The internal parts of the oil pump assembly are not serviced separately, excluding the spring. If the oil pump components are worn or damaged, replace the oil pump as an assembly.


NOTE
The oil pump pipe and screen are to be serviced as an assembly. Do not attempt to repair the wire mesh portion of the pump and screen assembly.

  1. Clean the parts in solvent.
  2.  
  3. Dry the parts with compressed air.

    Inspect the oil pump housing (413) and the cover (409) for cracks, excessive wear, scoring, or casting imperfections.
     
    Inspect the oil pump housing-to-engine block oil gallery surface for scratches or gouging.
     
    Inspect the oil pump housing for damaged bolt hole threads.
     
    Inspect the relief valve plug (416) and plug bore for damaged threads.
     
    Inspect the oil pump internal oil passages for restrictions.
     
    Inspect the drive gear (410) and driven gear (412) for chipping, galling or wear. Minor burrs or imperfections on the gears may be removed with a fine oil stone.
     
    Inspect the drive gear splines for excessive wear.
     
    Inspect the pressure relief valve (414) and bore for scoring or wear. The valve must move freely in the bore with no restrictions.
     
    Inspect the oil pump screen for debris or restrictions.
     
    Inspect the oil pump screen for broken or loose wire mesh.
     

  4.  

6.6L Engine

CAUTION
Wear safety glasses in order to avoid eye damage.

  1. Remove the oil pump gear cover bolts and oil pump gear cover.
  2.  
  3. Use a feeler gauge to measure the clearance between the gear teeth and the oil pump housing. The production clearance is 0.005-0.009 inch) (0.125-0.221 mm) and the service limit is 0.009 inch (0.221 mm).

    Click image to see an enlarged view

    Fig. Use a feeler gauge to measure the clearance between the gear teeth and the oil pump housing-6.6L engines

  4.  
  5. Replace the oil pump assembly if the clearance exceeds the service limit.
  6.  
  7. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear and the cover. The production clearance is 0.003-0.004 inch (0.064-0.109 mm) and the service limit is 0.004 inch (0.109 mm).

    Click image to see an enlarged view

    Fig. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear and the cover-6.6L engines

  8.  
  9. Replace the oil pump assembly if the clearance exceeds the service limit.
  10.  
  11. Calculate the driven gear shaft to bushing clearance.
    1. Measure the driven gear shaft outside diameter. The production specification is (0.785-0.786 inch (19.947-19.960 mm) and the service limit is 0.782 inch (19.86 mm).
    2.  
    3. Measure the driven gear bushing inside diameter. The production value is 0.787 inch (20 mm).
    4.  
    5. Calculate the driven gear shaft to bushing clearance. The service limit is 0.006 inch (0.14 mm)
    6.  

  12.  
  13. Replace the oil pump assembly if the clearance exceeds the service limit.

    Click image to see an enlarged view

    Fig. Measuring driven gear shaft and bushing-6.6L engines

  14.  
  15. Install the oil pump gear cover to the oil pump assembly.
  16.  
  17. Install the oil pump gear cover bolts.
    1. Tighten the oil pump gear cover bolts to 15 ft. lbs. (21 Nm).
    2.  

  18.  

8.1L Engine

CAUTION
Wear safety glasses in order to avoid eye damage.



Click image to see an enlarged view

Fig. Exploded view of oil pump-8.1L engines

  1. Clean the oil pump components in cleaning solvent.
  2.  
  3. Dry the components with compressed air.
  4.  
  5. Inspect the gears for the following:

    Scoring
     
    Chipping
     
    Galling
     
    Excessive wear
     

  6.  
  7. Inspect the oil pump housing for the following:

    Damaged bolt hole threads
     
    Worn oil pump driveshaft bore
     
    Scoring or excessive wear within the housing
     
    Worn driven gear shaft
     

  8.  
  9. Inspect for a collapsed pressure relief valve spring.
  10.  
  11. Inspect the pressure relief valve for scoring or wear. The valve should move freely within the bore of the housing.
  12.  

Removal & Installation



4.3L Engine
  1. Remove or disconnect the following:

    Oil pan
     
    Oil pump mounting bolt
     
    Oil pump
     

  2.  

To install:

  1. Inspect the oil pump locator pins for damage, and replace if required.
  2.  
  3. Clean and inspect the oil pump.
  4.  
  5. Position the oil pump onto the locator pins.
  6.  
  7. Install the oil pump bolt and tighten the bolt to 66 ft. lbs. (90 Nm).
  8.  
  9. Install the oil pan.
  10.  

4.8L, 5.3L & 6.0L Engines


Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-4.8L, 5.3L and 6.0L engines



Click image to see an enlarged view

Fig. Oil pump disassembly-4.8L, 5.3L and 6.0L engines

  1. Remove or disconnect the following:
    NOTE
    Do not allow dirt or debris to enter the oil pump assembly, cap ends as necessary.


    NOTE
    The internal parts of the oil pump assembly are not serviced separately (excluding the spring). If the oil pump components are worn or damaged, replace the oil pump as an assembly. Do not attempt to repair the wire mesh portion of the pump and screen assembly.



    Engine front cover
     
    Oil pan
     
    Oil pump screen bolt and nuts
     
    Oil pump screen with O-ring seal.
     
    O-ring seal from the pump screen. Discard the O-ring seal.
     
    Remaining crankshaft oil deflector nuts.
     
    Crankshaft oil deflector
     
    Oil pump bolts
     



    Oil pump
     

  2.  

To install:


NOTE
Inspect the oil pump and engine block oil gallery passages. These surfaces must be clear and free of debris or restrictions.

  1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block.
  2.  
  3. Install or connect the following:
    NOTE
    Lubricate a NEW oil pump screen O-ring seal with clean engine oil.


    NOTE
    Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump.



    Oil pump bolts. Tighten the oil pump bolts to 18 ft. lbs. (25 Nm).
     
    Crankshaft oil deflector
     



    NEW O-ring seal onto the oil pump screen
     

  4.  
  5. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs.
  6.  
  7. Install or connect the following:

    Oil pump screen
     
    Oil pump screen bolt and the deflector nuts. Tighten the bolt to 106 inch lbs. (12 Nm) and the nuts to 18 ft. lbs. (25 Nm).
     
    Oil pan
     
    Engine front cover
     

  8.  

6.6L Engine
  1. Drain the engine oil
  2.  
  3. Remove or disconnect the following:

    Engine flywheel housing (2WD vehicles)
     
    Engine front cover
     
    Lower and upper oil pans
     
    Oil pump pipe and screen and gasket
     

  4.  
  5. Block the crankshaft from turning with a wooden dowel.
    NOTE
    The crankshaft reluctor and oil pump drive gear are timed together at the factory. Do NOT remove the reluctor from the oil pump drive gear or damage the reluctor teeth.



    Oil pump driven gear nut
     
    Oil pump driven gear
     



    Oil pump drive gear and crankshaft reluctor assembly using a brass drift and tapping as close to the center of the reluctor assembly
     
    3 hex head and 1 Allen head bolt
     
    Oil pump
     
    Oil pump O-ring seal
     
    Oil pump gear cover bolts and cover
     

  6.  
  7. Measure the clearance between the gear teeth and oil pump housing using a feeler gauge. The production clearance is 0.0049-0.0087 in. (0.125-0.221mm) and the service limit is 0.0087 in. (0.221mm). Replace the pump if the clearance exceeds the service limit.
  8.  
  9. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear and the cover. The production clearance is 0.0025-0.0043 in. (0.064-0.109mm) and the service limit is 0.0043 in. (0.109mm). Replace the pump if the clearance exceeds the service limit.
  10.  
  11. Calculate the driven gear shaft-to-bushing clearance:
    1. Measure the driven gear shaft outside diameter. The production specification is 0.7853-0.7858 in. (19.947-19.960mm) and the service limit is 0.7819 in. (19.86mm).
    2.  
    3. Measure the driven gear bushing inside diameter. The production value is 0.7874 in. (20mm).
    4.  
    5. Calculate the driven gear shaft-to-bushing clearance. The service limit is 0.0055 in. (0.14mm).
    6.  
    7. Replace the pump if the clearance exceeds the service limit.

      Click image to see an enlarged view

      Fig. Exploded view of the oil pump mounting-6.6L engines

    8.  

  12.  

To install:

  1. Install or connect the following:

    Oil pump gear cover and bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    New O-ring seal for the oil pump
     
    Oil pump and bolts. Tighten to 15 ft. lbs. (20 Nm).
     

  2.  
  3. Check the oil pump drive gear for wear and replace the gear pin if necessary.

    Click image to see an enlarged view

    Fig. Installing the oil pump drive gear-6.6L engines



    Oil pump drive gear and reluctor
     
    Oil pump driven gear and nut. Block the crankshaft from moving, then tighten to 74 ft. lbs. (100 Nm)
     
    Oil pump pipe and screen gasket to the oil pump (AWD vehicle)
     
    Oil pump pipe and screen (AWD vehicle)
     
    Oil pump pipe and screen bolts and nuts (AWD vehicle). Tighten to 18 ft. lbs. (25 Nm).
     
    Engine front cover
     
    Engine flywheel housing (AWD vehicle)
     
    Upper and lower oil pans
     

  4.  
  5. Refill the crankcase with oil.
  6.  

8.1L Engine
  1. Remove or disconnect the following:

    Oil pan
     
    Oil pump screen bolt
     
    Oil pump, retainer and driveshaft. Discard the driveshaft retainer
     
    Crankshaft oil deflector nuts
     
    Crankshaft oil deflector
     
    Oil pump bolts
     
    Oil pump
     

  2.  
  3. Clean and inspect the oil pump

    Click image to see an enlarged view

    Fig. Oil pump removal-8.1L engines

  4.  

To install:

  1. Install the crankshaft oil deflector. Tighten the nuts to 37 ft. lbs. (50 Nm).
    NOTE
    Always replace the retainer between the oil pump and the shaft, when installing the oil pump. During assembly, install a new oil pump driveshaft retainer. To ease installation, slightly heat the retainer to above room temperature.

  2.  
  3. Assemble the oil pump, driveshaft and a new retainer.
  4.  
  5. Install or connect the following:

    Oil pump, positioning it on the locating pins
     
    Oil pump bolt and tighten to 56 ft. lbs. (75 Nm)
     
    Oil pan
     

  6.  
  7. Refill the engine crankcase
  8.  
  9. Disable the ignition system; crank engine for approximately 10 seconds to aid in priming the oil pump and reducing the risk of engine damage.
    NOTE
    If the oil pump does not build up oil pressure almost immediately, remove the pan and check for a loose oil pump-to-pick-up tube attachment. If necessary dismantle the pump and pack the pump cavity with petroleum jelly. Running the engine without measurable oil pressure will cause extensive damage.

  10.  

 
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