Hyundai Coupes/Sedans 1986-1993 Repair Guide

Oil Pump

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REMOVAL & INSTALLATION



Whenever the oil pump is disassembled or the cover removed, the gear cavity must be filled with petroleum jelly for priming purposes. Do not use grease.

1468cc and 1495cc Engines
  1. Disconnect the negative battery cable. Remove the timing belt.
  2.  
  3. Remove the oil pan.
  4.  
  5. Remove the oil screen.
  6.  
  7. Unbolt and remove the front case assembly.
  8.  
  9. Remove the oil pump cover.
  10.  
  11. Remove the inner and outer gears from the front case.
  12.  

The outer gear has no identifying marks to indicate direction of rotation. Clean the gear and mark it with an indelible marker.

  1. Remove the plug, relief valve spring and relief valve from the case.
  2.  

To install:
  1. Check the front case for damage or cracks. Replace the front seal. Replace the oil screen O-ring. Clean all parts thoroughly with a safe solvent.
  2.  
  3. Check the pump gears for wear or damage. Clean the gears thoroughly and place them in position in the case to check the clearances. There is a crescent-shaped piece between the 2 gears.
  4.  
  5. Check that the relief valve can slide freely in the case.
  6.  
  7. Check the relief valve spring for damage. The relief valve free length should be 1.8 in. (47mm). Load length should be 13.4 lbs. at 1.6 in. (40mm).
  8.  
  9. Thoroughly coat both oil pump gears with clean engine oil and install them in the correct direction of rotation.
  10.  
  11. Install the pump cover and torque the bolts to 6-8 ft. lbs. (8-12 Nm).
  12.  
  13. Coat the relief valve and spring with clean engine oil, install them and tighten the plug to 30-36 ft. lbs. (39-49 Nm).
  14.  
  15. Position a new front case gasket, coated with sealer, on the engine and install the front case. Torque the bolts to 8-11 ft. lbs. (12-15 Nm). Note that the bolts have different shank lengths. Use the following guide to determine which bolts go where. Bolts marked:
  16.  

1468cc Engine


A: 0.08 in. (20mm)
 
B: 1.2 in. (30mm)
 
C: 2.4 in. (60mm)
 

1495cc Engine


A: 0.98 in. (25mm)
 
B: 1.18 in. (30mm)
 
C: 1.77 in. (45mm)
 
D: 2.36 in. (60mm)
 

  1. Coat the lips of a new seal with clean engine oil and slide it along the crankshaft until it touches the front case. Drive it into place with a seal driver.
  2.  
  3. Install the sprocket, timing belt and pulley.
  4.  
  5. Install the oil screen.
  6.  
  7. Thoroughly clean both the oil pan and engine mating surfaces. Apply a 1 / 8 in. (3mm) wide bead of RTV sealer in the groove of the oil pan mating surface.
  8.  
  9. Tighten the oil pan bolts to 60-72 inch lbs. Connect the negative battery cable.
  10.  

1596cc, 1796cc and 1997cc Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Oil pump and pan assemblies-1596cc, 1796cc and 1997cc engines

  1. Remove the front engine mount bracket and accessory drive belts.
  2.  
  3. Remove timing belt upper and lower covers.
  4.  
  5. Remove the timing belt and crankshaft sprocket.
  6.  
  7. Remove the oil pan.
  8.  
  9. Remove the oil screen and gasket.
  10.  
  11. Remove and tag the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
  12.  
  13. On 1596cc and 1796cc engines, remove the plug cap using tool MD998162 or equivalent, and remove the oil pressure switch.
  14.  
  15. Remove the front case cover and oil pump assembly. If necessary, the silent shaft can come out with the assembly. Disassemble as required.
  16.  

To install:
  1. Thoroughly clean all gasket material from all mounting surfaces.
  2.  
  3. Apply engine oil to the entire surface of the gears or rotors.
  4.  
  5. On engines with silent shaft, install the drive/driven gears with the 2 timing marks aligned.
  6.  
  7. Assemble the front case cover and oil pump assembly to the engine block using a new gasket. On 1596cc and 1796cc engines, assemble the front case cover and oil pump assembly using tool MD998285 or equivalent, on the front end of the crankshaft. Tighten the bolts to specification.
  8.  
  9. Install the oil screen with new gasket.
  10.  
  11. Install the oil pan and timing belts.
  12.  
  13. Connect the negative battery cable and check for adequate oil pressure.
  14.  

2351cc Engine

See Figures 2 through 8

  1. Disconnect the negative battery cable. Remove the timing belt.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Removing the front case assembly-2351cc engine



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Fig. Fig. 3: Removing the oil pump cover from the front case-2351cc engine



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Fig. Fig. 4: Oil pump case with gears removed-2351cc engine

  1. Remove the oil pump cover and gears.
  2.  
  3. Remove the relief valve plug, spring and plunger.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Oil pump gear timing mark alignment-2351cc engine



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Fig. Fig. 6: Oil seal guide tool installation-2351cc engine



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Fig. Fig. 7: Front case bolt lengths and identification-2351cc engine



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Fig. Fig. 8: Tightening the relief plug-2351cc engine

  1. Thoroughly clean all parts in a safe solvent and check for wear and damage.
  2.  
  3. Clean all orifices and passages.
  4.  
  5. Place the gear back in the pump body and check clearances.

    Gear teeth-to-body-0.10-0.15mm
     
    Driven gear end-play-0.06-0.12mm
     
    Drive gear-to-bearing (front end)-0.020-0.045mm
     
    Drive gear-to-bearing (rear end)-0.043-0.066mm.
     

  6.  

If gear replacement is necessary, the entire pump body must be replaced.

  1. Check the relief valve spring for wear or damage. Free length should be 47mm; load/length should be 9.5 lbs. at 40mm.
  2.  

To install:
  1. Assemble the pump components. Make sure the gears are installed with the mating marks aligned.
  2.  
  3. Install the timing belt. Connect the negative battery cable.
  4.  

2972cc Engine

See Figures 9, 10 and 11

  1. Disconnect the negative battery cable. Remove the dipstick.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Oil pump and pan assemblies-2972cc engine



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Fig. Fig. 10: On the 2972cc engine, use this tool to remove the oil pressure switch

  1. Raise the vehicle and support safely. Remove the timing belt, drain the engine oil and remove the oil pan from the engine. Remove the oil pickup.
  2.  



Click image to see an enlarged view

Fig. Fig. 11: Oil pump mounting bolt locations-2972cc engine

  1. Remove the oil pump mounting bolts and remove the pump from the front of the engine. Note the different length bolts and their position in the pump for installation.
  2.  

To install:
  1. Clean the gasket mounting surfaces of the pump and engine block.
  2.  
  3. Prime the pump by pouring fresh oil into the pump and turning the rotors. Using a new gasket, install the oil pump on the engine and torque all bolts to 11 ft. lbs. (15 Nm).
  4.  
  5. Install the balancer and crankshaft sprocket to the end of the crankshaft.
  6.  
  7. Clean out the oil pickup or replace, if necessary. Replace the oil pickup gasket ring and install the pickup to the pump.
  8.  
  9. Install the timing belt, oil pan and all related parts.
  10.  
  11. Install the dipstick. Fill the engine with the proper amount of oil.
  12.  
  13. Connect the negative battery cable and check the oil pressure.
  14.  

 
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