ION 2006-2007

Oil Pump

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Inspection



  1. With the timing chain front cover and the oil pump body cover removed, use a feeler gauge to measure the clearance between the driven rotor and pump body. Clearance should not exceed 0.011 in. (0.277mm).
  2.  
  3. Use a feeler gauge to measure the clearance between the both rotor tips. Clearance should not exceed 0.006 in. (0.150mm).
  4.  
  5. Using Plastigage® or a feeler gauge, temporarily install the pump cover and measure the rotor-to-cover clearance. Clearance should not exceed 0.005 in. (0.128mm).
  6.  
  7. If necessary, replace the pump components and/or the front cover assembly.

    Click image to see an enlarged view

    Fig. Use a feeler gauge to measure the clearance between the driven rotor and pump body



    Click image to see an enlarged view

    Fig. Use a feeler gauge to measure the clearance between both rotor tips



    Click image to see an enlarged view

    Fig. Temporarily install the pump cover and measure the rotor-to-cover clearance

  8.  

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the drive belt.
  6.  
  7. Remove the accessory drive belt tensioner bolts.
  8.  
  9. Remove the accessory drive belt tensioner.
  10.  
  11. Remove the idler pulley bolts.
  12.  
  13. Remove the idler pulley.
  14.  
  15. Remove the alternator bracket and lift hook assembly bolts.
  16.  
  17. Remove the alternator bracket and lift hook assembly.
  18.  
  19. Remove the engine front cover bolts.
  20.  
  21. Remove the long water pump bolt.
  22.  
  23. Remove the engine front cover and gaskets.
  24.  
  25. Remove the crankshaft front cover oil seal with an appropriate tool.
  26.  
  27. Disassemble the pressure relief valve.
  28.  
  29. Remove the oil pump gerotor cover and bolts.
  30.  
  31. Clean all of the parts in cleaning solvent. Remove varnish, sludge and dirt.
  32.  
  33. Inspect the oil pump for wear and scoring.
  34.  

To install:

  1. Lubricate all oil pump parts with engine oil.
  2.  
  3. Install the inner gear into the outer gear.
    NOTE
    If gears are improperly installed in the front cover, the gerotor cover will not bolt on.

  4.  
  5. Install the gears together into the front cover with the hub of the center gear facing the front cover.
  6.  
  7. Install the oil pump gerotor cover and bolts. Tighten to 53 inch lbs. (6 Nm).
  8.  
  9. Install the pressure relief valve piston.
  10.  
  11. Install the pressure relief valve spring. Tighten the pressure relief valve plug to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the engine front cover with a new gasket.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  14.  
  15. Install the long water pump bolt. Tighten to 18 ft. lbs. (25 Nm).
  16.  
  17. Install the engine front cover bolts. Tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the alternator bracket and lift hook assembly. Tighten the bolts to 31 ft. lbs. (42 Nm).
  20.  
  21. Install the idler pulley. Tighten the bolts to 16 ft. lbs. (22 Nm).
  22.  
  23. Install the accessory drive belt tensioner. Tighten the bolts to 24 ft. lbs. (32 Nm).
  24.  
  25. Install the drive belt.
  26.  
  27. Connect the negative battery cable.
  28.  

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

    Negative battery cable
     
    Air cleaner assembly
     
    Right front wheel and splash shield
     
    Accessory drive belt
     
    Crankshaft damper pulley
     
    Belt tensioner
     

  6.  
  7. Install an engine support fixture.

    Right front engine mount
     
    Front cover bolts and the 13mm bolt under the water pump
     
    Front cover
     
    Oil pump cover plate
     
    Drive rotor and driven rotor
     
    Pressure relief valve
     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Whenever the oil pump is installed, the assembly must be packed with petroleum jelly in order to prime the pump.



    New relief valve into the cover bore, if removed. Coat the valve with clean engine oil and tap it into the bore. Torque the plug to 30 ft. lbs. (40 Nm).
     



    Drive and driven rotors into the pump with the chamfer toward the front oil seal
     
    Oil pump body cover using new bolts and torque the bolts to 53 inch lbs. (6 Nm)
     
    Front cover with a new oil seal and torque the perimeter and center bolts to 19 ft. lbs. (25 Nm) and the lower center bolt to 89 inch lbs. (10 Nm)
     
    Right side engine mount and torque the bolts to 41 ft. lbs. (55 Nm)
     

  2.  
  3. Remove the engine support fixture.

    Drive belt tensioner and torque the bolts 37 ft. lbs. (50 Nm)
     
    Crankshaft damper pulley and torque the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees
     
    Accessory drive belt
     
    Right front splash shield and wheel
     
    Air cleaner assembly
     
    Negative battery cable
     

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

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the accessory drive belt tensioner bolt.
  6.  
  7. Remove the accessory drive belt tensioner.
  8.  
  9. Remove the engine front cover bolts.
  10.  
  11. Remove the long water pump bolt.
  12.  
  13. Remove the engine front cover and gaskets.
  14.  
  15. Remove the crankshaft front cover oil seal with an appropriate tool.
  16.  
  17. Remove or disconnect the following:

    Oil pump cover plate
     
    Drive rotor and driven rotor
     
    Pressure relief valve
     

  18.  

To install:


NOTE
Whenever the oil pump is installed, the assembly must be packed with petroleum jelly in order to prime the pump.

  1. Install or connect the following:

    Drive and driven rotors into the pump with the chamfer toward the front oil seal
     
    Oil pump body cover using new bolts and torque the bolts to 53 inch lbs. (6 Nm)
     

  2.  
  3. Install the engine front cover with a new gasket.
  4.  
  5. Install the long water pump bolt. Tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the engine front cover bolts. Tighten to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the accessory drive belt tensioner. Tighten to 33 ft. lbs. (45 Nm).
  10.  
  11. Fill the engine with clean oil and replace the oil filter.
  12.  
  13. Start the vehicle and check for leaks, repair if necessary.
  14.  

 
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