Kia Sportage 2005-06

Oil Pump

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Removal & Installation



2.0L Engine


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Fig. Oil pump - 2.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the drive belts.
  6.  
  7. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
  8.  
  9. Remove the timing belt.

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    Fig. Remove the bolt (B) and timing belt idler (A) - 2.0L engine

  10.  
  11. Remove the bolt (B) and timing belt idler (A).
  12.  
  13. Remove the oil pan and oil screen.
  14.  
  15. Remove the alternator.
  16.  
  17. Remove the air conditioner compressor tensioner bracket.
  18.  
  19. Remove the four bolts securing the front case to the engine assembly.
  20.  
  21. Remove the front case and oil pump as an assembly.
  22.  
  23. Remove the bolts from the rear of the pump housing, then separate the housing and cover.
  24.  
  25. Remove the inner rotor and outer rotor.
  26.  

To install:

  1. Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
  2.  
  3. Install the oil pump cover to front case with the 7 bolts. Tighten to 5.9-8.8 Nm(4-6 ft. lbs.)
  4.  
  5. Check that the oil pump turns freely.
  6.  
  7. Place a new front case gasket on the cylinder block.
  8.  
  9. Apply engine oil to the lip of the oil pump seal. Then, install the oil pump onto the crankshaft. When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.

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    Fig. Oil pump bolt length identification - 2.0L engine

  10.  
  11. Note the bolt length as shown in the accompanying illustration.

    A: 25mm (0.984 in.)
     
    B: 30mm (1.181 in.)
     
    C: 38mm (1.496 in.), (D): 45mm (1.772 in.)
     

  12.  
  13. Tighten to 19.6-26.5 (14-19 ft. lbs.).
  14.  
  15. Apply a light coat of oil to the front case oil seal lip. Using the SST(09214-32000), install the front case oil seal.
  16.  
  17. Install the air conditioner compressor tensioner bracket (A).
  18.  
  19. Install the alternator.
  20.  
  21. Install the oil screen, tighten to 14.7-21.6 Nm (11-16 ft. lbs.).
  22.  
  23. Install the oil pan. Tighten to 9.8-11.8N-m (7-9 ft. lbs.).
    NOTE
    Clean the oil pan gasket mating surfaces.

  24.  
  25. Install the timing belt idler. Tighten to 42.2-53.9N-m (31-40 ft. lbs.)
  26.  
  27. Install the timing belt.
  28.  
  29. Install the drive belts.
  30.  
  31. Fill with engine oil.
  32.  

2.7L Engines


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Fig. Lubrication system components - 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain engine oil.
  4.  
  5. Remove right front wheel.
  6.  
  7. Remove right side cover.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the alternator from engine.
  12.  
  13. Remove the drive belt.
  14.  
  15. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower cover.
  16.  
  17. Remove the timing belt.
  18.  
  19. Remove the oil pump case. Remove the bolts from the pump housing, then separate the housing and cover. 
  20.  
  21. Remove the inner and outer rotors. 
  22.  

To install:

  1. Place the inner and outer rotors into front case with the marks facing the oil pump cover side. 
  2.  
  3. Install the oil pump cover to front case with the 8 bolts. Tighten to 8-12 Nm (6-9 ft. lbs.).
  4.  
  5. Check that the oil pump turns freely.
  6.  
  7. Install the oil pump on the cylinder block.
  8.  
  9. Remove any old liquid gasket and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. 
  10.  
  11. Using a razor blade and gasket scraper, remove all the old liquid gasket from the gasket surfaces and sealing grooves. 
  12.  
  13. Using a non-residue solvent, clean both sealing surfaces. 
  14.  
  15. Apply liquid gasket to the oil pump as shown in the illustration. Use liquid gasket MS 721-40A, or equivalent.

    Click image to see an enlarged view

    Fig. Liquid gasket application - 2.7L engine

  16.  
  17. To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.  Instead, reapply liquid gasket after removing the residue. After assembly, wait at least 30 minutes before filling the engine with oil. 
  18.  
  19. Place a new O-ring on the cylinder block. 
  20.  
  21. Engage the spline teeth of the oil pump drive gear with large teeth of the crankshaft, and slide the oil pump on the crankshaft. 
  22.  
  23. Install the oil pump with 5 bolts. Uniformly tighten the bolts in several passes. Tighten to 12-15 Nm (9-11 ft. lbs.).

    Click image to see an enlarged view

    Fig. Oil pump bolt length identification. A-8x25, B-8x35, C-8x45 - 2.7L engine

  24.  
  25. Apply a light coat of oil to the seal lip. Using a seal driver, install the oil seal.

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    Fig. Seal installation - 2.7L engine

  26.  
  27. Install the oil pan and oil screen. 
  28.  
  29. Install the timing belt. 
  30.  
  31. Install the drive belt.
  32.  
  33. Install the alternator. 
  34.  
  35. Install the front exhaust pipe. 
  36.  
  37. Install the right front wheel.
  38.  
  39. Fill engine with oil.
  40.  
  41. Start engine and check for leaks.
  42.  
  43. Recheck engine oil level.
  44.  

Inspection



2.7L Engine


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Fig. Lubrication system components - 2.7L engine

  1. Drain the engine oil and following proper procedures, remove the oil pump housing from the engine.
  2.  
  3. Remove the screws from the pump housing, then separate the housing and cover. 
  4.  
  5. Remove the inner and outer rotors. 
  6.  
  7. Inspect rotor side clearance. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Side clearance: 0.04-0.095 mm (0.0016-0.0037 in.).
  8.  
  9. If the side clearance is greater than maximum, replace the rotors as a set.  If necessary, replace the front case.
  10.  
  11. If the tip clearance is greater than maximum, replace the rotor as a set.
  12.  
  13. Inspect rotor body clearance. Using a feeler gauge, measure the clearance between the outer rotor and body. Body clearance: 0.100-0.181 mm (0.0039-0.0017 in.).
  14.  
  15. If the body clearance is greater than maximum, replace the rotors as a set.  If necessary, replace the front case.
  16.  

2.0L Engine


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Fig. Oil pump - 2.0L engine

  1. Drain the engine oil and following proper procedures, remove the oil pump housing from the engine.
  2.  
  3. Remove the bolts from the rear of the pump housing, then separate the housing and cover.
  4.  
  5. Remove the inner rotor and outer rotor.
  6.  
  7. Inspect the rotor side clearance. Using a feeler gauge and precision straightedge, measure the clearance between the rotors and precision straight edge.

    Click image to see an enlarged view

    Fig. Measuring rotor side clearance



    Outer rotor: 0.04-0.09mm (0.0016-0.0035 in.)
     
    Inner rotor; 0.04-0.085mm (0.0016-0.0033 in.)
     

  8.  
  9. If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.

    Click image to see an enlarged view

    Fig. Measuring rotor tip clearance

  10.  
  11. Inspect the rotor tip clearance. Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips. Tip clearance: 0.025-0.069mm (0.0010-0.0027 in.). If the tip clearance is greater than maximum, replace the rotors as a set.

    Click image to see an enlarged view

    Fig. Measuring rotor body clearance

  12.  
  13. Inspect the rotor body clearance. Using a feeler gauge, measure the clearance between the outer rotor and body. Body clearance: 0.120-0.185mm (0.0047-0.0073 in.). If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.
  14.  

 
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