Cavalier, Sunfire 2001-2005

Oil Pump

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Removal & Installation



2.2L (Vin 4) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the crankcase.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan
     
    Oil pump and extension shaft

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump mounting to engine block-2.2L (VIN 4) engine

     

  6.  

To install:


WARNING
A plastic extension shaft retainer connects the oil pump driveshaft to the oil pump. Heat the extension shaft retainer in hot water prior to assembly. Be sure the retainer does not crack upon installation.

  1. Fill the oil pump cavities with petroleum jelly before installing the gears into the pump body.
  2.  
  3. Install or connect the following:

    Extension shaft and oil pump. Torque the oil pump-to-bearing cap bolt to 32 ft. lbs. (43 Nm) and the upper oil pump drive bolt to 18 ft. lbs. (25 Nm).
     
    Oil pan
     
    Negative battery cable
     

  4.  
  5. Refill the crankcase.
  6.  
  7. Start the engine and check oil pressure and check for leaks.
  8.  

2.2L (VIN F) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the engine front cover as follows:
    1. Remove the front wheel.
    2.  
    3. Remove the engine splash shield.
    4.  
    5. Remove the drive belt.
    6.  
    7. Use crankshaft holding tool J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt.
    8.  
    9. Remove the crankshaft balancer bolt and discard. Remove the balancer.
    10.  
    11. Remove the drive belt tensioner.
    12.  
    13. Remove the water pump-to-front cover bolts.
    14.  
    15. Remaining front cover-to-engine bolts, the cover and gasket.
    16.  

  4.  
  5. Remove or disconnect the following:

    Oil pressure relief valve
     
    Oil pump cover
     
    Oil pump gears

    Click image to see an enlarged view

    Fig. Oil pump assembly-2.2L (VIN F) engine

     

  6.  

To install:

  1. Install or connect the following:

    Oil pump gears
     
    Oil pump cover and tighten the bolts to 53 inch lbs. (6 Nm)
     
    Oil pressure relief valve and tighten the plug to 30 ft. lbs. (40 Nm).
     

  2.  
  3. Install the engine front cover as follows:
    1. Install front cover gasket, cover and cover-to-engine bolts.
    2.  
    3. Install the water pump-to-front cover bolts. Tighten all the cover bolts to 15 ft. lbs. (20 Nm).
    4.  
    5. Install the drive belt tensioner and tighten the bolt to 33 ft. lbs. (45 Nm).
    6.  
    7. Install the crankshaft balancer and bolt.
    8.  
    9. Use crankshaft holding tool J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus an additional 75 degrees.
    10.  
    11. Install the engine splash shield.
    12.  
    13. Install the drive belt.
    14.  
    15. Install the front wheel.
    16.  

  4.  

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Install an engine support fixture.
  6.  
  7. Drain the crankcase.
  8.  
  9. Remove or disconnect the following:

    Oil pan
     
    Balance shaft chain cover and tensioner
     
    Oil pump
     

  10.  
  11. Disassemble the oil pump as follows:
    1. Remove the oil pump cover.
    2.  
    3. Remove the pump gear.
    4.  
    5. Remove the sub-assembly from the balance shaft assembly
    6.  
    7. Remove the gerotor from the oil pump housing.
    8.  
    9. Remove the oil pump from the balance shaft housing.
    10.  
    11. Remove the pressure relief valve.

      Click image to see an enlarged view

      Fig. Using a feeler gauge to check the chain tension-2.4L engine



      Click image to see an enlarged view

      Fig. Exploded view of the oil pump assembly mounting-2.4L engine

    12.  

  12.  

To install:

  1. Lubricate the gears with clean engine oil.
  2.  
  3. Assemble the oil pump as follows:
    1. Place the gerotor gear into the housing.
    2.  
    3. Fill the oil pump cavities with petroleum jelly.
    4.  
    5. Install the pressure relief valve using a 9 / 16 in. deep well socket to seat the valve.
    6.  
    7. Connect the pump housing to the balance shaft assembly.
    8.  
    9. Install the pump cover.
    10.  

  4.  
  5. Install or connect the following:
    NOTE
    A brass feeler gauge must be used to ensure that correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will allow for incorrect measurements.



    Oil pump. Torque the bolts to 40 ft. lbs. (54 Nm).
     
    Balance shaft chain tensioner and chain
     

  6.  
  7. Adjust the chain tension as follows:
    1. Insert a 0.40 in. (1mm) brass feeler between the chain guide and the chain.
    2.  
    3. Press the guide against the chain using about 3 pounds of force.
    4.  
    5. Torque the chain tensioner fastener to 115 inch lbs. (13 Nm).
    6.  

  8.  
  9. Install or connect the following:

    Balance shaft chain cover. Torque the nut and bolt to 115 inch lbs. (13 Nm).
     
    Oil pan
     
    Negative battery cable.
     

  10.  
  11. Refill the crankcase.
  12.  
  13. Start the vehicle and verify oil pressure and no leaks.
  14.  

 
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