Neon, 2000-2005

Oil Pump

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Removal & Installation



2.0L 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
     
    Crankshaft damper
     
    Timing belt
     
    Timing belt tensioner
     
    Camshaft sprocket and rear timing belt cover
     
    Oil pan
     
    Crankshaft sprocket, using Tool 6795 and Insert Tool C-4685-C2
     
    Oil pickup tube
     
    Oil pump
     
    Front crankshaft seal
     
    Oil pump cover screws and lift the cover off
     
    Oil pump rotors
     

  6.  
  7. Wash all parts in a solvent; then, inspect carefully for damage or wear, as follows:
    1. Inspect the mating surface of the oil pump should be smooth. Replace the pump cover, if scratched or grooved.

      Click image to see an enlarged view

      Fig. Exploded view of the oil pump and related component mounting-2.0L engine

      Exploded view of the oil pump and related component mounting-2.0L engine

      Click image to see an enlarged view

      Fig. Exploded view of the oil pump assembly-2.0L engine

      Exploded view of the oil pump assembly-2.0L engine
    2.  
    3. Lay a straightedge across the pump cover surface. If a 0.003 inch (0.076mm) feeler gauge can be inserted between the cover and the straightedge, the cover should be replaced.

      Click image to see an enlarged view

      Fig. Use a feeler gauge and straightedge to check the oil pump cover for warpage-2.0L engine

      Use a feeler gauge and straightedge to check the oil pump cover for warpage-2.0L engine
    4.  
    5. Measure the thickness and diameter of the outer rotor. If the outer rotor thickness measures 0.301 inch (7.64mm) or less, or if the diameter is 3.148 inch (79.95mm) or less, replace the outer rotor.

      Click image to see an enlarged view

      Fig. Use calipers to measure the outer rotor thickness-2.0L engine

      Use calipers to measure the outer rotor thickness-2.0L engine

      Click image to see an enlarged view

      Fig. and the inner rotor thickness-2.0L engine

      and the inner rotor thickness-2.0L engine
    6.  
    7. If the inner rotor measures 0.301 inch (7.64mm) or less, replace the inner rotor.
    8.  
    9. Slide the outer rotor into the pump housing, press to one side with your fingers and measure the clearance between the rotor and the housing. If the measurement is 0.015 inch (0.39mm) or more, replace the housing only if the outer rotor is within specification.

      Click image to see an enlarged view

      Fig. Measure the outer rotor clearance in the housing-2.0L engine

      Measure the outer rotor clearance in the housing-2.0L engine
    10.  
    11. Install the inner rotor into the pump housing, If the clearance between the inner and outer rotors is 0.008 inch (0.203mm) or more, replace both rotors.
    12.  
    13. Place a straightedge across the face of the pump housing, between the bolt holes. If a feeler gauge of 0.004 inch (0.102mm) or more can be inserted between the rotors and the straightedge, replace the pump assembly.
    14.  
    15. Inspect the oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper.
    16.  
    17. The relief valve spring has a free length of about 2.39 inch (60.7mm) and should test between 18-19 lbs. (8.1-8.6 kg) when compressed to 1.60 inch (40.6mm). Replace the spring, if it falls outside of specifications.
    18.  
    19. If the oil pressure is low and the pump is within specifications, inspect for worn engine bearings or for other reasons for oil pressure loss.
    20.  

  8.  

To install:

  1. Assemble the pump, using new parts as required, as follows:
    1. Install the inner rotor with the chamfer facing the cast iron oil pump cover.
    2.  
    3. Apply Mopar® gasket maker to the oil pump.
    4.  
    5. Install the oil ring into the oil pump body discharge passage.

      Click image to see an enlarged view

      Fig. Apply a small amount of gasket maker to the pump body cover mounting surface-2.0L engine

      Apply a small amount of gasket maker to the pump body cover mounting surface-2.0L engine
    6.  

  2.  
  3. Prime the oil pump before installation by filling the rotor cavity with engine oil.
  4.  
  5. Install or connect the following:
    WARNING
    The front crankshaft seal MUST be out of the pump to align or damage may result.



    Oil pump, align the rotor flats with the crankshaft flats. Torque the pump bolts to 21 ft. lbs. (28 Nm).
     



    New front crankshaft seal, using Seal Driver Tool 6780
     
    Crankshaft sprocket, using a Crankshaft Sprocket Installer Tool 6792
     
    Oil pump pickup tube
     
    Oil pan
     
    Rear timing belt cover and camshaft sprocket
     
    Timing belt tensioner
     
    Timing belt and front cover
     
    Crankshaft damper
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the engine and check for leaks; then, recheck the fluid level and add as necessary.
  10.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing belt.
  6.  
  7. Remove the timing belt rear cover.
  8.  
  9. Remove the oil pan.
  10.  
  11. Remove the crankshaft sprocket using tools 6793 and C-4685-C2.
  12.  
  13. Remove the crankshaft key.
  14.  
  15. Remove the oil pick-up tube.
  16.  
  17. Remove the oil pump and front crankshaft seal.

    Click image to see an enlarged view

    Fig. Oil pump retainer locations-2.4L engines

    Oil pump retainer locations-2.4L engines

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-2.4L engines

    Exploded view of the oil pump assembly-2.4L engines
  18.  
  19. Disassemble the pump as follows:
    1. Remove the oil pump cover fasteners, and lift off the cover.
    2.  
    3. Remove the pump rotors.
    4.  
    5. Wash all parts in a suitable solvent and inspect carefully for damage or wear.
    6.  

  20.  
  21. Inspect the pump components as follows:
    1. Inspect the mating surface of the oil pump. The surface should be smooth. Replace the pump cover if it is scratched or grooved.
    2.  
    3. Lay a straightedge across the pump cover surface. If a 0.001 inch (0.025 mm) feeler gauge can be inserted between the cover and straight edge, the cover should be replaced.
    4.  
    5. Measure the thickness and diameter of the outer rotor. If the outer rotor thickness measures 0.421 inch (10.699 mm) or less, or if the diameter is 3.382 inch (85.924 mm) or less, replace the outer rotor.

      Click image to see an enlarged view

      Fig. Check the oil pump cover flatness-2.4L engines

      Check the oil pump cover flatness-2.4L engines

      Click image to see an enlarged view

      Fig. Check the oil pump outer rotor thickness-2.4L engines

      Check the oil pump outer rotor thickness-2.4L engines

      Click image to see an enlarged view

      Fig. Check the oil pump inner rotor thickness-2.4L engines

      Check the oil pump inner rotor thickness-2.4L engines

      Click image to see an enlarged view

      Fig. Apply gasket maker to the oil pump as shown and install the O-ring into oil pump body discharge passage -2.4L engines

      Apply gasket maker to the oil pump as shown and install the O-ring into oil pump body discharge passage -2.4L engines
    6.  

  22.  
  23. Assemble the pump as follows:
    1. Assemble the pump, using new parts as required. Install the inner rotor with the chamfer facing the cast iron oil pump cover.
    2.  
    3. Prime the oil pump before installation by filling the rotor cavity with engine oil.
    4.  
    5. Install the cover and tighten the fasteners to 118 inch lbs. (13 Nm).
    6.  

  24.  
  25. Install the pump as follows:
    1. Make sure all the surfaces are clean and free of oil and dirt.
    2.  
    3. Apply gasket maker to the oil pump as illustrated. Install the O-ring into oil pump body discharge passage.
    4.  
    5. Prime the oil pump with engine oil before installation.
    6.  
    7. Align the oil pump rotor flats with the flats on crankshaft.
    8.  
    9. Install the oil pump to the block.
      CAUTION
      To align, the front crankshaft seal MUST be out of the pump, or damage may result.

    10.  
    11. Install a new front crankshaft seal using tool 6780.
    12.  
    13. Install the crankshaft key.
      CAUTION
      The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of tool 6792 is required to set the sprocket to its original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage.

    14.  
    15. Install the crankshaft sprocket using tool 6792.
    16.  
    17. Install the oil pump pick-up tube.
    18.  
    19. Install the oil.
    20.  
    21. Install timing belt rear cover.
    22.  
    23. Install the timing.
    24.  

  26.  
  27. Connect the negative battery cable.
  28.  

 
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