Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Oil Pump

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Inspection



2.4L Engine
  1. Clean all the parts thoroughly. The mating surface of the oil pump should be smooth. Replace the pump cover if is scratched or grooved.
  2.  
  3. Lay a straightedge across the pump cover surface. If a 0.001 in. (0.025mm) feeler gauge can be inserted between the cover and the straight edge, the cover should be replaced.
  4.  
  5. Measure the thickness and diameter of the outer rotor. If the outer rotor thickness measures 0.370 in. (9.40mm) or less, or if the diameter is 3.148 in. (79.95mm) or less, replace the outer rotor.
  6.  
  7. If the inner rotor measures 0.370 in. (9.40mm) or less, replace the inner rotor.
  8.  
  9. Slide the outer rotor into the pump housing, press it to one side with your fingers and measure the clearance between the rotor and the housing. If the measurement is 0.015 in. (0.39mm) or more, replace the housing only if the outer rotor is within specification.
  10.  
  11. Install the inner rotor into the pump housing. If the clearance between the inner and the outer rotors is 0.008 in. (0.203mm) or more, replace both rotors.
  12.  
  13. Place a straightedge across the face of the pump housing, between the bolt holes. If a feeler gauge of 0.004 in. (0.102mm), or more can be inserted between the rotors and the straightedge, replace the pump assembly, ONLY if the rotors are within specifications.
  14.  
  15. Inspect the oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper.
  16.  
  17. The relief valve spring has a free length of approximately 2.39 inches (60.7mm). It should test between 18-19 pounds when compressed to 1.60 inches (40.5mm). Replace the spring that fails to meet specifications.
  18.  
  19. If the oil pressure is low and the pump is within specifications, inspect for worn engine bearings or other reasons for the oil pressure loss.
  20.  

2.7L Engine
  1. Disassemble the oil pump.
  2.  
  3. Clean all the oil pump components.
  4.  
  5. Inspect the mating surface of the oil pump housing and cover. Replace the oil pump if it is deeply scratched or grooved (minor surface scratches and polishing is normal).
  6.  
  7. Lay a straightedge across the pump cover surface. If a 0.001 in. (0.025mm) feeler gauge can be inserted between the cover and the straight edge, the cover should be replaced.
  8.  
  9. Measure the thickness and diameter of the outer rotor. If the outer rotor thickness measures 0.373 in. (9.474mm) or less, or if the diameter is 3.5108 in. (89.174mm) or less, replace the outer rotor.
  10.  
  11. If the inner rotor measures 0.373 in. (9.474mm) or less, replace the inner rotor.
  12.  
  13. Slide the outer rotor into the body, press it to one side with your fingers and measure the clearance between the rotor and body. If the measurement is 0.015 in. (0.39mm) or more, replace the body only if the outer rotor is within specifications.
  14.  
  15. Install the inner rotor into the body. If the clearance between the inner and the outer rotors is 0.008 in. (0.20mm) or more, replace both rotors.
  16.  
  17. Place a straightedge across the face of the body, between the bolt holes. If a feeler gauge of 0.003 in. (0.077mm) or more can be inserted between the rotors and the straightedge, replace the pump assembly ONLY if the rotors are within specification.
  18.  
  19. Inspect the oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper.
  20.  
  21. The relief valve spring has a free length of approximately 1.95 in. (49.5mm). It should test between 23-25 pounds when compressed to 1.34 in. (34mm). Replace the spring if it fails to meet specifications.
  22.  
  23. Assemble the oil pump.
  24.  

Precautions




NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

Removal & Installation



2.0L And 2.4L Engines

The oil drawn up through the pick-up tube is pressurized by the pump and routed through the full flow filter to the main oil galley running the length of the cylinder block. The oil pick-up, pump and check valve provide oil flow to the main oil gallery. A vertical hole at the No. 5 bulkhead routes pressurized oil through a restrictor up past a cylinder head bolt to an oil galley running the length of the cylinder head. The camshaft journals are slotted to allow pressurized oil to pass into the bearing cap cavities. Small holes in the bearing caps direct oil to the camshaft lobes.

Click image to see an enlarged view

Fig. Oil pump and related parts-2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module as follows:

    Negative battery cable
     
    Crankshaft damper
     
    Timing belt and tensioner
     
    Camshaft sprocket
     
    Rear timing belt cover
     
    Oil pan
     
    Oil pick up tube
     
    Oil pump and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

  1. Prime the oil pump before installation.
  2.  
  3. Install or connect the following:

    Oil pump with the flats aligned with the crankshaft flats and torque the bolts to 21 ft. lbs. (28 Nm)
     
    New front crankshaft seal
     
    Crankshaft sprocket
     
    Oil pick up tube and oil pan
     
    Camshaft sprocket
     
    Rear timing belt cover
     
    Timing belt and tensioner
     
    Front timing belt cover
     
    Crankcase damper
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    WARNING
    The front cover/oil pump mounting bolts may be different sizes and must be reinstalled in their original locations. Remove and tag the front cover mounting bolts.



    Negative battery cable
     
    Timing belt
     
    Oil pan
     
    Crankshaft sprocket
     
    Oil pump pick-up tube and O-ring
     
    Oil pump and front crankshaft seal
     

  8.  
  9. Inspect the oil pump case for damage and remove the rear cover.
  10.  
  11. Remove the pump rotors and inspect the inside of the case for excessive wear or scoring.
  12.  
  13. Check that the oil relief plunger slides smoothly and check for a broken spring.
  14.  

To install:

  1. Clean all parts well. Be sure the block and pump surfaces are clean and free of old sealer.
  2.  
  3. Assemble the pump using new parts as required with clean oil. Align the marks on the inner and outer rotors when assembling.
  4.  
  5. Install the pump back cover and torque the screws to 88 inch lbs. (10 Nm).
  6.  
  7. Reinstall the pump relief valve, spring, gasket and valve cap. Torque the valve cap to 30-33 ft. lbs. (41-44 Nm).
  8.  
  9. Apply gasket maker to the engine block mounting surface of the oil pump body.
  10.  
  11. Install the oil ring into the discharge passage of the pump body.
  12.  
  13. Prime the oil pump before installation by filling the rotor cavity with clean engine oil.
  14.  
  15. Align the flats of the oil pump rotor with the flats on the crankshaft as you install the pump to the engine block.
  16.  
  17. Install or connect the following:

    Oil pump-to-engine block bolts and torque to 17-21 ft. lbs. (23-28 Nm)
     
    New front oil seal
     
    Crankshaft sprocket
     
    Oil pump pickup tube and O-ring and torque the oil pump pickup tube screw to 21 ft. lbs. (28 Nm)
     
    Oil pan
     
    Timing belt and covers
     
    Crankshaft damper
     
    New oil filter
     

  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Test run the vehicle to check for leaks. An oil pressure gauge should be installed to verify proper engine oil pressure.
  22.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the engine support module as follows:

    Negative battery cable
     
    Oil filter
     
    Oil pressure switch
     
    Oil pan and screen
     
    Flange bolt
     
    Relief plug, spring and plunger
     
    Oil filter bracket
     
    Oil pump case
     
    Front case gasket
     
    Oil pump cover
     
    Oil pump driven gear
     
    Oil pump drive gear
     
    Oil pump
     

  8.  
  9. Clean all mating surfaces of any residual gasket material.
  10.  

To install:

  1. Prime the oil pump before installation.
  2.  
  3. Install or connect the following:

    New oil seal into the front case
     
    Oil pump
     
    Oil pump drive gear
     
    Oil pump driven gear
     
    Oil pump cover
     
    Front case gasket
     
    Oil pump case
     
    Oil filter bracket
     
    Relief plunger, spring, gasket and plug
     
    Flange bolt
     
    Oil pan and screen
     
    Oil pressure switch
     
    New oil filter
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

The oil drawn up through the pick-up tube is pressurized by the pump and routed through the full flow filter to the main oil galley running the length of the cylinder block. The oil pick-up, pump, and check valve provide oil flow to the main oil gallery. A vertical hole at the No. 5 bulkhead routes pressurized oil through a restrictor up past a cylinder head bolt to an oil galley running the length of the cylinder head. The camshaft journals are slotted to allow pressurized oil to pass into the bearing cap cavities. Small holes in the bearing caps direct oil to the camshaft lobes.

Click image to see an enlarged view

Fig. Oil pump and related parts-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module:

    The negative battery cable
     
    The Crankshaft damper
     
    The timing belt and tensioner
     
    The camshaft sprocket
     
    The rear timing belt cover
     
    The oil pan
     
    The oil pick up tube
     
    The oil pump and discard the gasket
     

  6.  
  7. Clean all the mating surfaces of any residual gasket material.
  8.  

To install:

  1. Prime the oil pump before installation.
  2.  
  3. Install or connect the following:

    The oil pump with the flats aligned with the crankshaft flats and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The new front crankshaft seal
     
    The crankshaft sprocket
     
    The oil pick up tube and oil pan
     
    The camshaft sprocket
     
    The rear timing belt cover
     
    The timing belt and tensioner
     
    The front timing belt cover
     
    The Crankshaft damper
     
    The negative battery cable
     

  4.  
  5. Fill the engine with the proper amount of clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module as follows:

    Negative battery cable
     
    Crankshaft damper
     
    Timing chain cover
     
    Timing chain and sprockets
     
    Oil pan
     
    Oil pick up tube and O-ring and make certain that the crankshaft is at 60 degrees After Top Dead Center (ATDC)
     
    Oil pump

    Click image to see an enlarged view

    Fig. Oil pump and pick-up tube-2.7L engine



    Click image to see an enlarged view

    Fig. Crankshaft positioned at 60 degrees ATDC-2.7L engine

     

  6.  

To install:

  1. Prime the pump before installation by filling the rotor cavity with clean engine oil.
  2.  
  3. Install or connect the following:

    Oil pump over the crankshaft and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Oil pick up tube with a new O-ring and torque the bolt to 21 ft. lbs. (28 Nm)
     
    Oil pan with a new gasket
     
    Timing chain and sprockets
     
    Timing chain and cover
     
    Crankshaft damper
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module:

    The negative battery cable
     
    The Crankshaft damper
     
    The timing chain cover
     
    The timing chain and sprockets
     
    The oil pan
     
    The oil pick up tube and O-ring and make certain that the crankshaft is at 60° After Top Dead Center (ATDC)
     
    The oil pump

    Click image to see an enlarged view

    Fig. Oil pump and pick-up tube-2.7L engine



    Click image to see an enlarged view

    Fig. Crankshaft positioned at 60 degrees ATDC-2.7L engine

     

  6.  

To install:

  1. Prime the pump before installation by filling the rotor cavity with clean engine oil.
  2.  
  3. Install or connect the following:

    The oil pump over the crankshaft and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The oil pick up tube with a new O-ring and torque the bolt to 21 ft. lbs. (28 Nm)
     
    The oil pan with a new gasket
     
    The timing chain and sprockets
     
    The timing chain and cover
     
    The Crankshaft damper
     
    The negative battery cable
     

  4.  
  5. Fill the engine with the proper amount of clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the engine support module as follows:

    Negative battery cable
     
    Oil filter
     
    Oil pressure switch
     
    Oil filter bracket
     
    Lower and upper oil pan
     
    Baffle plate
     
    Oil screen and gasket
     
    Baffle plate
     
    Relief spring and plunger
     
    Front crankshaft oil seal
     
    Oil pump case
     
    Oil pump cover
     
    Oil pump outer and inner rotors
     
    Oil pump case
     

  8.  
  9. Clean all mating surfaces of any residual gasket material.
  10.  

To install:

  1. Prime the oil pump before installation.
  2.  
  3. Install or connect the following:

    Oil pump case
     
    Inner and outer rotors
     
    Oil pump cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Oil pump case assembly
     
    New front crankshaft oil seal
     
    Relief plunger and spring
     
    Baffle plate
     
    Oil screen with a new gasket
     
    Baffle plate
     
    Upper oil pan and cover
     
    Lower oil pan
     
    Oil filter bracket with a new gasket
     
    Oil pressure switch
     
    New oil filter
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

 
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