Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Oil Pump 2

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Removal & Installation



4.8L, 5.3L & 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

    Click image to see an enlarged view

    Fig. Oil pump removal-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

     
    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

    Click image to see an enlarged view

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

     

  8.  



Click image to see an enlarged view

Fig. Oil pump removal-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

    Click image to see an enlarged view

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

     

  8.  

  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

    Click image to see an enlarged view

    Fig. Oil pump removal-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

     
    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
     



    Click image to see an enlarged view

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

  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.

    Oil pump screen, screen bolt and reflector nuts. Tighten the bolt (4) to 106 inch lbs. (12 Nm) and the oil deflector nuts (2) to 18 ft. lbs. (25 Nm).
     
    Oil pan
     
    Engine front cover
     

  6.  

  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

    Click image to see an enlarged view

    Fig. Oil pump removal-4.8L, 5.3L, 6.0L



    Click image to see an enlarged view

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

     
    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 25 Nm (18 ft. lbs.).
     
    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 the oil pump screen. Install the oil pump screen bolt and the deflector nuts. Tighten the oil pump screen bolt (4) to 12 Nm (106 inch lbs.). Tighten the crankshaft oil deflector nuts (2) to 25 Nm (18 ft. lbs.).
  8.  
  9. Install the engine oil pan.
  10.  
  11. Install the engine front cover.

    Click image to see an enlarged view

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

  12.  

  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

    Click image to see an enlarged view

    Fig. Oil pump removal-4.8L, 5.3L, 6.0L



    Click image to see an enlarged view

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

     
    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 25 Nm (18 ft. lbs.).
     
    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 the oil pump screen. Install the oil pump screen bolt and the deflector nuts. Tighten the oil pump screen bolt (4) to 12 Nm (106 inch lbs.). Tighten the crankshaft oil deflector nuts (2) to 25 Nm (18 ft. lbs.).
  8.  
  9. Install the engine oil pan.
  10.  
  11. Install the engine front cover.

    Click image to see an enlarged view

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

  12.  



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.  

4.8L, 5.3L, 6.0L & 6.2L Engines


Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-4.8L, 5.3L, 6.0L and 6.2L engines



Click image to see an enlarged view

Fig. Oil pump disassembly-4.8L, 5.3L, 6.0L and 6.2L 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.  

5.0L, 5.7L And 7.4L Engines
  1. Remove or disconnect the following:

    Oil pan
     
    Oil pump attaching bolt, if equipped
     
    Pick-up tube nut/bolt
     
    Pump along with the pick-up tube and shaft, as necessary
     

  2.  
  3. Clean all sealing surfaces
  4.  

To install:

  1. Ensure that the pump pick-up tube is tight in the pump body. If the tube should come loose, oil pressure will be lost and oil starvation will occur. If the pick-up tube is loose it should be replaced.
  2.  
  3. If the pump has been disassembled and is being replaced or for any reason oil has been removed, it must be primed. It can either be filled with oil before installing the cover plate and oil kept within the pump during handling or the entire pump cavity can be filled with petroleum jelly.
    NOTE
    If the pump is not primed, the engine could be damaged before it receives adequate lubrication when the engine is started.

  4.  
  5. Install or connect the following:

    Pump, aligning the pump shaft with the oil pump drive gear as necessary. Torque oil pump/pick-up tube retainer(s) to 65 ft. lbs. (90 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.  

5.7L & 7.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Oil pan
     
    Oil pump attaching bolt, if equipped
     
    Pick-up tube nut/bolt
     
    Pump along with the pick-up tube and shaft, as necessary
     

  4.  
  5. Clean all sealing surfaces
  6.  

To install:

  1. Ensure that the pump pick-up tube is tight in the pump body. If the tube should come loose, oil pressure will be lost and oil starvation will occur. If the pick-up tube is loose it should be replaced.
  2.  
  3. If the pump has been disassembled and is being replaced or for any reason oil has been removed, it must be primed. It can either be filled with oil before installing the cover plate and oil kept within the pump during handling or the entire pump cavity can be filled with petroleum jelly.
    NOTE
    If the pump is not primed, the engine could be damaged before it receives adequate lubrication when the engine is started.

  4.  
  5. Install or connect the following:

    Pump, aligning the pump shaft with the oil pump drive gear as necessary. Torque oil pump/pick-up tube retainer(s) to 65 ft. lbs. (90 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.  

6.5L Engine
  1. Drain the engine oil
  2.  
  3. Remove or disconnect the following:

    Oil pan
     
    Oil pump to crankshaft rear main bearing attaching bolt
     
    Oil pump and hex drive
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-6.5L diesel engines

  1. Inspect the oil pan pick up tube and screen for damage and the hex drive for cracks.
  2.  
  3. Install or connect the following:

    Oil pump and extension shaft to the engine. Align the extension shaft hex with the drive hex, the oil pump should push easily into place.
     
    Oil pump bolt and tighten to 65 ft. lbs. (90 Nm)
     
    Oil pan
     

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

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil
  4.  
  5. Remove or disconnect the following:

    Oil pan
     
    Oil pump to crankshaft rear main bearing attaching bolt
     
    Oil pump and hex drive
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-6.5L diesel engines

  1. Inspect the oil pan pick up tube and screen for damage and the hex drive for cracks.
  2.  
  3. Install or connect the following:

    Oil pump and extension shaft to the engine. Align the extension shaft hex with the drive hex, the oil pump should push easily into place.
     
    Oil pump bolt. Torque the bolt to 65 ft. lbs. (90 Nm).
     
    Oil pan
     

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

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil
  4.  
  5. Remove or disconnect the following:

    Oil pan
     
    Oil pump to crankshaft rear main bearing attaching bolt
     
    Oil pump and hex drive
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-6.5L diesel engines

  1. Inspect the oil pan pick up tube and screen for damage and the hex drive for cracks.
  2.  
  3. Install or connect the following:

    Oil pump and extension shaft to the engine. Align the extension shaft hex with the drive hex, the oil pump should push easily into place.
     
    Oil pump bolt. Torque the bolt to 65 ft. lbs. (90 Nm).
     
    Oil pan
     

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

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil
  4.  
  5. Remove or disconnect the following:

    Oil pan
     
    Oil pump to crankshaft rear main bearing attaching bolt
     
    Oil pump and hex drive
     

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pump mounting-6.5L diesel engines

  1. Inspect the oil pan pick up tube and screen for damage and the hex drive for cracks.
  2.  
  3. Install or connect the following:

    Oil pump and extension shaft to the engine. Align the extension shaft hex with the drive hex, the oil pump should push easily into place.
     
    Oil pump bolt. Torque the bolt to 65 ft. lbs. (90 Nm).
     
    Oil pan
     

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

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.
    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.

    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 (4WD vehicle)
     
    Oil pump pipe and screen (4WD vehicle)
     
    Oil pump pipe and screen bolts and nuts (4WD vehicle). Tighten to 18 ft. lbs. (25 Nm).
     
    Engine front cover
     
    Engine flywheel housing (2WD vehicle)
     
    Upper and lower oil pans
     

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

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil
  4.  
  5. Remove or disconnect the following:

    Engine flywheel housing (2WD vehicles)
     
    Engine front cover
     
    Upper oil pan
     
    Oil pump pipe and screen and gasket
     

  6.  
  7. 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
     

  8.  
  9. 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.
  10.  
  11. 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.
  12.  
  13. 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.
    8.  

  14.  

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.

    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 (4WD vehicle)
     
    Oil pump pipe and screen (4WD vehicle)
     
    Oil pump pipe and screen bolts and nuts (4WD vehicle). Tighten to 18 ft. lbs. (25 Nm)
     
    Engine front cover
     
    Engine flywheel housing (2WD vehicle)
     
    Upper oil pan
     

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

  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.  

  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 (4WD vehicle)
     
    Oil pump pipe and screen (4WD vehicle)
     
    Oil pump pipe and screen bolts and nuts (4WD vehicle). Tighten to 18 ft. lbs. (25 Nm).
     
    Engine front cover
     
    Engine flywheel housing (2WD vehicle)
     
    Upper and lower oil pans
     

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

 
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