Kia Sportage 1998-02

Oil Pump

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Inspection



2.0L (VIN 3) Engine
Disassembly
  1. Following proper procedures, remove the oil pump from the engine and place the oil pump on a workbench.
  2.  
  3. Remove seven screws on the oil pump cover.
  4.  
  5. Remove the oil pump cover.
  6.  
  7. Remove oil pump inner rotor.
  8.  
  9. Remove oil pump outer rotor.
  10.  
  11. Remove pressure relief valve as follows:
    1. Remove the snap ring.
    2.  
    3. Remove the spring seat.
    4.  
    5. Remove the pressure spring.
    6.  
    7. Remove the pressure plunger.
    8.  

  12.  
  13. Remove oil seal.
  14.  

Inspection
  1. Check for a distorted or damaged oil pump body or cover. Replace if necessary.
  2.  
  3. Check for worn or damaged plunger. Replace if necessary.
  4.  
  5. Check weak of broken plunger spring. Measure the free length of the spring. If the free length measurement is not at least 1.791 inch, replace the plunger spring.
  6.  
  7. Check the pump housing and pump gears as follows:
    1. Measure gear to body clearance. Maximum clearance should not exceed 0.004 inch
    2.  
    3. Measure the tooth tip clearance. Maximum clearance should not exceed. 0.007 inches.
    4.  
    5. Measure oil pump outer rotor to pump body clearance. Maximum clearance should not exceed 0.008 inch
    6.  
    7. If any of the above measurements are not within specifications, replace the worn pump body and/or pump gears as necessary.
    8.  

  8.  

Reassembly
  1. Replace the O-ring.
  2.  
  3. Install the oil seal as follows:
    1. Apply clean engine oil to the oil seal and pump body.
    2.  
    3. Carefully press the seal into the housing.
    4.  

  4.  
  5. Install the pressure relief valve as follows:
    1. Install the spring in the spring seat and the pressure plunger.
    2.  
    3. Install the relief valve into the pump body.
    4.  

  6.  
  7. Install the oil pump outer rotor.
  8.  
  9. Install the oil pump inner rotor.
  10.  
  11. Install the oil pump cover as follows:
    1. Apply thread locking compound to the cover mounting screw threads.
    2.  
    3. Attach the oil pump cover to the oil pump body.
    4.  
    5. Tighten the mounting screws to 66 inch lbs. (7.5 Nm).
    6.  

  12.  
  13. Following proper procedures, reinstall the oil pump onto the engine.

    Click image to see an enlarged view

    Fig. Exploded view of oil pump assembly - 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Measure oil pump outer rotor to pump body clearance as shown - 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Measure oil pump tooth tip clearance as shown - 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Replace pump body O-ring - 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Measure gear to pump clearance as shown - 2.0L (VIN 3) Engine

  14.  

Removal & Installation




NOTE
The oil pump is externally-mounted, but still requires the removal of the oil pan to disconnect the oil pump strainer.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Alternator belt
     
    Fresh air duct from the radiator
     
    Upper radiator hose
     
    Clutch fan and shroud
     
    Splash guard
     
    Loosen the A/C drive belt
     
    Power steering belt
     
    Timing belt covers
     
    Lower timing belt pulley and lock bolt and place a support under the front axle
     
    Axle attaching bolts and lower the axle enough to gain access to the oil pan
     
    Transmission under cover
     
    Oil pan
     
    Oil pump
     

  10.  

To install:



Click image to see an enlarged view

Fig. Be sure the oil pump O-ring is in the proper location prior to installation

  1. Clean the engine block, oil pan and baffle pan surfaces of any gasket material.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pump.
  4.  


NOTE
Do not allow sealant to get in the oil passages when applying sealant to the contact surface.

  1. Install or connect the following:

    New O-ring and mount the oil pump to the engine. Torque the -A- bolts to 16 ft. lbs. (22 Nm) and the -B- bolts to 33 ft. lbs. (45 Nm).
     

  2.  
  3. Remove the upper and lower A/C compressor mounting bolts.
  4.  
  5. Loosen the A/C compressor bracket.

    Power steering pump bracket and hand tighten the bolts
     
    A/C compressor bracket
     
    A/C compressor. Torque the mounting bolts to 17 ft. lbs. (23 Nm).
     
    Torque the power steering pump bracket bolts to 24 ft. lbs. (33 Nm).
     
    Power steering pump. Torque the bolts to 43 ft. lbs. (58 Nm).
     
    Timing belt gear on the crankshaft. Torque the large crank bolt to 119 ft. lbs. (162 Nm).
     
    Oil baffle after applying sealant to the mating surface. Torque the bolt to 84 inch lbs. (9.5 Nm).
     
    Oil strainer. Torque the bolts to 84 inch lbs. (9.5 Nm).
     
    Oil pan
     
    Transmission under cover. Torque the bolts to 84 inch lbs. (9.5 Nm).
     
    Both gusset plates. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Raise the front axle into position. When aligned properly, torque the bolts to 123 ft. lbs. (167 Nm).
     
    Timing belt and cover
     
    Alternator belt
     
    A/C and power steering belt and adjust as needed
     
    Splash shield
     
    Upper radiator hose
     
    Clutch fan and shroud as an assembly
     
    Air duct to the top of the radiator
     
    Engine under cover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  6.  
  7. Properly fill the cooling system.
  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Start the engine, check for leaks, and repair if necessary.
  12.  


NOTE
The oil pump is externally-mounted, but still requires the removal of the oil pan to disconnect the oil pump strainer.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section .
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Alternator belt
     
    Fresh air duct from the radiator
     
    Upper radiator hose
     
    Clutch fan and shroud
     
    Splash guard
     
    Loosen the A/C drive belt
     
    Power steering belt
     
    Timing belt covers
     
    Lower timing belt pulley and lock bolt and place a support under the front axle
     
    Axle attaching bolts and lower the axle enough to gain access to the oil pan
     
    Transmission under cover
     
    Oil pan
     
    Oil pump
     

  10.  

To install:

Click image to see an enlarged view

Fig. Be sure the oil pump O-ring is in the proper location prior to installation

  1. Clean the engine block, oil pan and baffle pan surfaces of any gasket material.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pump.
    NOTE
    Do not allow sealant to get in the oil passages when applying sealant to the contact surface.

  4.  
  5. Install or connect the following:

    New O-ring and mount the oil pump to the engine. Torque the -A- bolts to 16 ft. lbs. (22 Nm) and the -B- bolts to 33 ft. lbs. (45 Nm).
     

  6.  
  7. Remove the upper and lower A/C compressor mounting bolts.
  8.  
  9. Loosen the A/C compressor bracket.

    Power steering pump bracket and hand tighten the bolts
     
    A/C compressor bracket
     
    A/C compressor. Torque the mounting bolts to 17 ft. lbs. (23 Nm).
     
    Torque the power steering pump bracket bolts to 24 ft. lbs. (33 Nm).
     
    Power steering pump. Torque the bolts to 43 ft. lbs. (58 Nm).
     
    Timing belt gear on the crankshaft. Torque the large crank bolt to 119 ft. lbs. (162 Nm).
     
    Oil baffle after applying sealant to the mating surface. Torque the bolt to 84 inch lbs. (9.5 Nm).
     
    Oil strainer. Torque the bolts to 84 inch lbs. (9.5 Nm).
     
    Oil pan
     
    Transmission under cover. Torque the bolts to 84 inch lbs. (9.5 Nm).
     
    Both gusset plates. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Raise the front axle into position. When aligned properly, torque the bolts to 123 ft. lbs. (167 Nm).
     
    Timing belt and cover
     
    Alternator belt
     
    A/C and power steering belt and adjust as needed
     
    Splash shield
     
    Upper radiator hose
     
    Clutch fan and shroud as an assembly
     
    Air duct to the top of the radiator
     
    Engine under cover. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  10.  
  11. Properly fill the cooling system.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the engine, check for leaks, and repair if necessary.
  16.  


NOTE
The oil pump is externally-mounted, but still requires the removal of the oil pan to disconnect the oil pump strainer.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Alternator belt
     
    Fresh air duct from the radiator
     
    Upper radiator hose
     
    Clutch fan and shroud
     
    Splash guard
     
    Loosen the A/C drive belt
     
    Power steering belt
     
    Timing belt covers
     
    Lower timing belt pulley and lock bolt and place a support under the front axle
     
    Axle attaching bolts and lower the axle enough to gain access to the oil pan
     
    Transmission under cover
     
    Oil pan
     
    Oil pump
     

  10.  

To install:

Click image to see an enlarged view

Fig. Be sure the oil pump O-ring is in the proper location prior to installation

  1. Clean the engine block, oil pan and baffle pan surfaces of any gasket material.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pump.
    NOTE
    Do not allow sealant to get in the oil passages when applying sealant to the contact surface.

  4.  
  5. Install or connect the following:

    New O-ring and mount the oil pump to the engine. Torque the -A- bolts to 16 ft. lbs. (22 Nm) and the -B- bolts to 33 ft. lbs. (45 Nm)
     

  6.  
  7. Remove the upper and lower A/C compressor mounting bolts.
  8.  
  9. Loosen the A/C compressor bracket.

    Power steering pump bracket and hand tighten the bolts
     
    A/C compressor bracket
     
    A/C compressor. Torque the mounting bolts to 17 ft. lbs. (23 Nm)
     
    Torque the power steering pump bracket bolts to 24 ft. lbs. (33 Nm)
     
    Power steering pump. Torque the bolts to 43 ft. lbs. (58 Nm)
     
    Timing belt gear on the crankshaft. Torque the large crank bolt to 119 ft. lbs. (162 Nm)
     
    Oil baffle after applying sealant to the mating surface. Torque the bolt to 84 inch lbs. (9.5 Nm)
     
    Oil strainer. Torque the bolts to 84 inch lbs. (9.5 Nm)
     
    Oil pan
     
    Transmission under cover. Torque the bolts to 84 inch lbs. (9.5 Nm)
     
    Both gusset plates. Torque the bolts to 33 ft. lbs. (45 Nm)
     
    Raise the front axle into position. When aligned properly, torque the bolts to 123 ft. lbs. (167 Nm)
     
    Timing belt and cover
     
    Alternator belt
     
    A/C and power steering belt and adjust as needed
     
    Splash shield
     
    Upper radiator hose
     
    Clutch fan and shroud as an assembly
     
    Air duct to the top of the radiator
     
    Engine under cover. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  10.  
  11. Properly fill the cooling system.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the engine, check for leaks, and repair if necessary.
  16.  

 
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