GM Prizm/Nova 1985-1993 Repair Guide

Oil Pump

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REMOVAL & INSTALLATION



1985-88 VIN Code 4 Engine

See Figures 1 and 2

This procedure requires special-purpose tools which may not be in your everyday tool set. Snapring pliers (internal and external) and pulley removers of various sizes are available at most reputable tool outlets.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil pan as previously outlined.
  4.  
  5. Drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the water pump pulley bolts.
  2.  
  3. Remove the alternator bolts.
  4.  
  5. If equipped with power steering, remove the drive belt.
  6.  
  7. If equipped with air conditioning, loosen the air conditioning idler pulley and the adjustor. Remove the drive belt and then remove the idler pulley and adjustor.
  8.  
  9. Remove the alternator bolts and remove the alternator; place it or suspend it out of the way.
  10.  
  11. Remove the water pump pulley.
  12.  
  13. Disconnect the upper radiator hose at the engine.
  14.  
  15. Label and disconnect the vacuum hoses running through the work area.
  16.  
  17. Remove the No. 1 (upper) timing belt cover and its gasket.
  18.  
  19. Remove the No. 3 (middle) timing belt cover and its gasket.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the oil pump - 1985-88 VIN Code 4 engine

  1. Rotate the crankshaft to the TDC/compression position.
  2.  
  3. Elevate and safely support the vehicle on jackstands. Double check the placement of the stands and the stability of the car on the stands.
  4.  
  5. Remove the right splash shield.
  6.  
  7. Remove the flywheel cover.
  8.  
  9. Remove the crankshaft pulley. Block the flywheel to prevent the crank from turning.
  10.  
  11. Remove the No. 2 (lower) timing belt cover.
  12.  
  13. Mark the position of the camshaft and crankshaft timing pulleys on the timing belt and mark an arrow on the belt showing the direction of rotation.
  14.  
  15. Loosen the timing belt idler pulley bolt, move the pulley to release tension on the belt and tighten the bolt. This holds the pulley in the loosened position.
  16.  
  17. Slip the timing belt off the crankshaft timing pulley.
  18.  
  19. Remove the crankshaft timing pulley.
  20.  
  21. Remove the dipstick tube.
  22.  
  23. Remove the timing belt idler pulley.
  24.  
  25. Remove the bolts in the oil pump case and carefully remove the oil pump. It may require gentle tapping to loosen it; use only a plastic or rubber mallet.
  26.  

To install:
  1. When reinstalling, place the new gasket against the block and install the oil pump to the crankshaft with the spline teeth of the drive gear engaged with the large teeth of the crankshaft. Tighten the bolts to 18 ft. lbs.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Aligning the oil pump drive gear with the crankshaft - 1985-88 VIN Code 4 engine

  1. Install the timing belt idler pulley.
  2.  
  3. Install the dipstick tube.
  4.  
  5. Install the crankshaft timing pulley.
  6.  
  7. Install the timing belt. (Refer to: Timing Belt - REMOVAL & INSTALLATION later in this section.).
  8.  
  9. Install the lower belt cover.
  10.  
  11. Install the crankshaft pulley and tighten it to 87 ft. lbs.
  12.  
  13. Install the flywheel cover.
  14.  
  15. Install the right splash guard and lower the vehicle to the ground.
  16.  
  17. Install the middle and upper timing belt covers with their gaskets.
  18.  
  19. Reconnect the vacuum hoses.
  20.  
  21. Attach the water pump pulley; leave the bolts finger tight.
  22.  
  23. Position and secure the alternator.
  24.  
  25. If so equipped, install the air conditioning adjusting bolt, idler pulley and belt. Install the belt and adjust it to the proper tension.
  26.  
  27. Install the power steering belt and adjust it if so equipped.
  28.  
  29. Tighten the water pump bolts.
  30.  
  31. With a new gasket, install the oil pick-up and strainer assembly. Tighten the nuts and bolts to 6.8 ft. lbs.
  32.  
  33. Refill the cooling system.
  34.  
  35. Install the oil pan following procedures outlined previously.
  36.  
  37. Start the engine and check for leaks. Allow the engine to warm up fully and check the work area carefully under warm and cold conditions.
  38.  

1988 VIN Code 5 Engine

See Figures 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil pan as previously outlined.
  4.  
  5. Remove the oil pick-up and strainer.
  6.  
  7. Remove the oil pan baffle plate.
  8.  
  9. Drain the cooling system.
  10.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the accelerator cable or linkage.
  2.  
  3. Remove the cruise control actuator if so equipped.
  4.  
  5. Remove the washer tank.
  6.  
  7. Remove the upper radiator hose at the engine block.
  8.  
  9. Remove the power steering and/or the air conditioning drive belt(s).
  10.  
  11. Loosen the bolts to the water pump pulley and then remove the alternator drive belt.
  12.  
  13. Remove the spark plugs.
  14.  
  15. Rotate the crankshaft and position the engine at TDC/compression. The crankshaft mark aligns at zero and the camshaft, when viewed through the oil filler cap, has a small cavity pointing upward.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Aligning the engine at TDC/compression for No. 1 cylinder - 1988 VIN Code 5 engine

  1. Use a floor jack and a piece of wood to slightly elevate the engine. Remove the right engine mount; then remove the 3 bolts and remove the right reinforcing plate for the engine mount.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Arrows indicate the nuts and bolts holding the right engine mount and the reinforcing plate - 1988 VIN Code 5 engine

  1. Remove the water pump pulley.
  2.  
  3. Remove the crankshaft pulley. Counterhold the crankshaft or block the flywheel to prevent the crank from turning.
  4.  
  5. Remove the timing belt covers.
  6.  


WARNING
The timing belt cover bolts are different lengths and MUST be returned to the proper hole at reassembly. During removal, diagram or label each bolt and its correct position.

  1. Remove the timing belt guide.
  2.  
  3. Loosen the idler pulley bolt, push it all the way to the left and tighten the bolt. This removes tension from the belt.
  4.  
  5. Matchmark the belt and all the pulleys so that the belt may be reinstalled exactly as it was before. Mark an arrow on the belt showing direction of rotation.
  6.  
  7. Remove the timing belt from the lower pulley (crankshaft timing pulley). If you are careful, the belt may remain undisturbed on the camshaft pulleys.
  8.  
  9. Remove the idler pulley and spring.
  10.  
  11. Remove the crankshaft timing pulley.
  12.  
  13. Remove the PCV hose.
  14.  
  15. Remove the dipstick and tube.
  16.  
  17. Remove the 7 bolts in the oil pump and carefully remove the pump. If it is difficult to remove, tap it lightly with a plastic or rubber mallet. Do not pry it off or strike it with a metal hammer.
  18.  

To install:
  1. When reinstalling, place a new gasket on the block. Install the oil pump to the crankshaft with the spline teeth to the drive gear engaged with the large teeth of the crankshaft.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Correct positions for installation of the oil pump - 1988 VIN Code 5 engine and 1989-90 VIN Code 6 engine

  1. Install the 7 retaining bolts and tighten them to 16 ft. lbs.
  2.  
  3. Install the dipstick tube and dipstick.
  4.  
  5. Install the crankshaft timing pulley.
  6.  
  7. Install the timing belt idler pulley.
  8.  
  9. Install the timing belt. (Refer to Timing Belt - REMOVAL & INSTALLATION procedures in this section.)
  10.  
  11. Install the timing belt guide. It should install with the cupped side facing outward.
  12.  
  13. Make sure the gaskets are properly seated in the timing belt covers and reinstall the covers. Make sure each bolt is in the correct hole.
  14.  
  15. Install the crankshaft pulley. Again using a counterholding device, tighten the bolt to 101 ft. lbs.
  16.  
  17. Install the water pump pulley and tighten the bolts finger tight. Install the valve covers.
  18.  
  19. Install the right side engine mount. Tighten the nut to 38 ft. lbs. and the through bolt to 64 ft. lbs.
  20.  
  21. Install the reinforcement for the right motor mount and tighten the bolts to 31 ft. lbs.
  22.  
  23. Install the spark plugs.
  24.  
  25. Install the alternator drive belt and tighten the water pump pulley bolts.
  26.  
  27. Install and adjust the power steering and/or the air conditioner drive belts.
  28.  
  29. Connect the upper radiator hose.
  30.  
  31. Install the windshield washer reservoir.
  32.  
  33. If equipped with cruise control, reinstall the cruise control actuator.
  34.  
  35. Connect the accelerator cable or linkage.
  36.  
  37. Install the oil pan baffle plate. Clean the contact surfaces thoroughly, apply a bead of sealer to the baffle plate and press the baffle plate into position. Be very careful not to get any sealant into the oil passages.
  38.  
  39. Install the oil pick-up and strainer assembly. Install the PCV hose.
  40.  
  41. Install the oil pan, following procedures discussed in this section.
  42.  
  43. Using new gaskets, reconnect the exhaust pipe. Tighten the bolts to the catalytic converter to 32 ft. lbs. and the bolts to the exhaust manifold 46 ft. lbs.
  44.  
  45. Install the flywheel cover.
  46.  
  47. Install the stiffener plate and the center engine mount.
  48.  
  49. Refill the engine with oil.
  50.  
  51. Refill the coolant system.
  52.  
  53. Start the engine and check for leaks. Allow the engine to warm up to normal operating temperature and check the work area carefully for signs of seepage.
  54.  
  55. With the engine shut off, check the tension of the drive belts and adjust if necessary. Reinstall the splash guards under the car.
  56.  



Click image to see an enlarged view

Fig. Fig. 6: Detail of the oil pump system - 1988 VIN Code 5 engine

1989-92 All Engines

See Figure 5

  1. Disconnect the negative battery cable and elevate the vehicle. Safely support it on jackstands. Remove the splashshield(s).
  2.  
  3. Remove the protectors from the 2 center engine mount nuts and studs.
  4.  
  5. Remove the 2 center transaxle mount-to-center crossmember nuts.
  6.  
  7. Remove the 2 rear transaxle mount-to-main crossmember nuts.
  8.  
  9. Drain the engine oil.
  10.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. Remove the oil pan. Remove the oil pick-up and strainer assembly.
  2.  
  3. Lower the vehicle to the ground.
  4.  
  5. Depending on equipment, loosen the air conditioning compressor bracket, the power steering pump bracket and the alternator bracket as applicable. Remove the drive belts.
  6.  
  7. Remove the alternator from its mounts and place it out of the way. The wiring may be left attached.
  8.  
  9. Lift out the windshield washer fluid reservoir.
  10.  
  11. Support the engine. This may be done from above with tool J 28467-A or a chain hoist or from below with a floor jack. Be very careful of the jack 12.
  12.  
  13. Remove the through bolt in the right engine mount.
  14.  
  15. Remove the water pump pulley.
  16.  
  17. Lower the engine to its normal position.
  18.  
  19. Remove the crankshaft pulley.
  20.  
  21. Remove the timing belt covers.
  22.  
  23. Remove the timing belt guide from the crank pulley.
  24.  
  25. Loosen the idler pulley bolt, push it all the way to the left and tighten the bolt. This removes tension from the belt.
  26.  
  27. Matchmark the belt and all the pulleys so that the belt may be reinstalled exactly as it was before. Mark an arrow on the belt showing direction of rotation.
  28.  
  29. Remove the timing belt from the lower pulley (crankshaft timing pulley). If you are careful, the belt may remain undisturbed on the camshaft pulleys.
  30.  
  31. Remove the idler pulley and spring.
  32.  
  33. Remove the dipstick and dipstick tube.
  34.  
  35. Remove the crankshaft timing pulley.
  36.  
  37. Raise the vehicle and safely support it on jackstands.
  38.  
  39. Remove the 7 bolts holding the oil pump.
  40.  
  41. Remove the 7 bolts in the oil pump and carefully remove the pump. If it is difficult to remove, tap it lightly with a plastic or rubber mallet. Do not pry it off or strike it with a metal hammer.
  42.  

To install:
  1. When reinstalling, place a new gasket on the block. Install the oil pump to the crankshaft with the spline teeth to the drive gear engaged with the large teeth of the crankshaft.
  2.  
  3. Install the 7 retaining bolts and tighten them to 16 ft. lbs.
  4.  
  5. Lower the vehicle to the ground.
  6.  
  7. Install the timing belt idler pulley.
  8.  
  9. Install the dipstick tube and dipstick.
  10.  
  11. Install the timing belt. (Refer to Timing Belt - REMOVAL & INSTALLATION procedures in this section.)
  12.  
  13. Install the timing belt guide. It should install with the cupped side facing outward.
  14.  
  15. Make sure the gaskets are properly seated in the timing belt covers and reinstall the covers. Make sure each bolt is in the correct hole.
  16.  
  17. Install the crankshaft pulley. Tighten the bolt to 87 ft. lbs.
  18.  
  19. Elevate the motor to gain access to the water pump.
  20.  
  21. Install the water pump pulley.
  22.  
  23. Install the right engine mount through bolt. Tighten the through bolt to 64 ft. lbs. When the bolt is secure, the engine lifting apparatus may be removed.
  24.  
  25. Position and install the alternator.
  26.  
  27. Reinstall the drive belts for the alternator, power steering and air conditioning as applicable. Adjust the belts to the correct tension.
  28.  
  29. Raise the vehicle and safely support it on jackstands.
  30.  
  31. Install the oil pick-up and strainer assembly.
  32.  
  33. Apply a continuous bead of sealer (GM 1050026 or similar) to both sides of the new pan gasket.
  34.  
  35. Place the gasket on the pan and install the pan to the block. Tighten the bolts and nuts to 3.6 ft. lbs. (44 inch lbs.)
  36.  
  37. Install the 2 rear transaxle mount-to-main crossmember nuts and tighten them to 45 ft. lbs. Install the 2 center transaxle mount-to-center crossmember nuts and tighten them to 45 ft. lbs.
  38.  
  39. Install the protectors over the nuts and studs for the mounts.
  40.  
  41. Lower the vehicle to the ground.
  42.  
  43. Install the windshield washer fluid reservoir.
  44.  
  45. Refill the engine with the correct amount of fresh oil.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Start the engine and check for leaks. Allow the engine to warm up to normal operating temperature and check the work area carefully for signs of seepage.
  50.  
  51. With the engine shut off, check the tension of the drive belts and adjust if necessary. Reinstall the splash guard(s) under the car.
  52.  

1993

See Figure 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt and tensioner as outlined in this section.
  4.  
  5. Remove the oil pan and strainer as outlined in this section.
  6.  
  7. Remove the 1 bolt and the guide tube with the oil level indicator from the oil pump.
  8.  
  9. Remove the 7 bolts and the oil pump with the gasket from the cylinder block. If necessary, tap on the back side of the oil pump with a plastic or rubber faced hammer to break it loose from the cylinder block.
  10.  
  11. Remove the oil seal from the oil pump.
  12.  

To install:
  1. Apply clean engine oil to the new oil seal.
  2.  
  3. Install the new oil seal to the oil pump using tool J 35403 or equivalent. Coat the inside of the new oil seal with wheel bearing lubricant.
  4.  
  5. Install a new gasket to the cylinder block and install the oil pump to the crankshaft, engaging the spline teeth during installation. Tighten the bolts to 16 ft. lbs. (21 Nm).
  6.  

The oil pump bolts are 2 lengths. Make sure the 2 longer bolts are installed in the correct position to prevent leaks.

  1. Install the timing belt and belt tensioner as outlined in this section.
  2.  
  3. Install the engine oil pan and strainer as outlined in this section.
  4.  
  5. Install the guide tube and oil level indicator to the oil pump. Tighten the guide tube bolt to 80 inch lbs. (9 Nm)
  6.  
  7. Connect the negative battery cable.
  8.  



Click image to see an enlarged view

Fig. Fig. 7: Oil pump assembly - 1993 models

INSPECTION AND OVERHAUL



1989-93 All Engines

See Figures 8, 9, 10 and 11

  1. Remove the pump body cover.
  2.  
  3. Using a feeler gauge, measure the clearance between the driven gear and the pump body. If the clearance is greater than 0.0079 in. (0.20mm), replace the oil pump.
  4.  
  5. Using a feeler gauge, measure the clearance between both gear tips. The clearance should be a maximum of 0.012 in. (0.35mm).
  6.  
  7. If the clearance is greater than the maximum, replace the oil pump gear set.
  8.  
  9. Using a feeler gauge and a straightedge, measure the side clearance. The clearance should be a maximum of 0.004 in. (0.10mm).
  10.  
  11. If the clearance is greater than the maximum, replace the oil pump gear set and/or the pump body.
  12.  



Click image to see an enlarged view

Fig. Fig. 8: Oil pump cover



Click image to see an enlarged view

Fig. Fig. 9: Removing the snap ring



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Fig. Fig. 10: Measuring the clearance between the driven gear and pump body



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Fig. Fig. 11: Measuring the gear to pump body clearance

 
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