Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Oil Pump

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REMOVAL & INSTALLATION




CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

1.2L Engine

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Oil pump and components-1.2L engine

The oil pump is an integral part of the crankcase cover, located at the front of the engine.

  1. Raise and support the vehicle safely.
  2.  
  3. Drain the engine oil into a suitable container.
  4.  
  5. Remove the oil level gauge, the oil level gauge guide and the level gauge guide seal.
  6.  
  7. Disconnect the electrical harness from the alternator. Remove the alternator-to-engine mounting bolts, drive belt and the alternator from the engine.
  8.  
  9. Remove the crankshaft pulley bolt and the crankshaft pulley.
  10.  
  11. Remove the timing belt cover-to-engine bolts and the cover from the engine.
  12.  
  13. Remove the timing belt tensioner-to-engine bolts, the spring and the tensioner.
  14.  
  15. Using a piece of chalk, mark the rotating direction of the timing belt.
  16.  
  17. Remove the crankshaft drive plate and the timing belt.
  18.  
  19. Remove the camshaft sprocket-to-camshaft bolts and the sprocket from the camshaft.
  20.  
  21. Remove the inner timing belt cover-to-engine bolts and the cover from the engine.
  22.  
  23. From under the engine, remove the flywheel housing cover-to-engine bolts and the cover from the engine.
  24.  
  25. Remove the oil pan-to-engine bolts and the pan from the engine; discard the gasket. Remove the oil strainer-to-engine bolts and the strainer assembly from the engine.
  26.  
  27. Remove the water pump cover-to-crankcase cover bolts and the water pump cover. Use a screwdriver to lock the balance shaft, then remove the water pump impeller.
  28.  
  29. Remove the crankcase cover-to-engine bolts and the cover from the engine.
  30.  
  31. Remove the oil pump cover-to-crankcase cover bolts, the cover, the outer rotor and the inner rotor with the shaft.
  32.  

To install:
  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Inspect the oil pump parts for wear and/or damage; replace the parts if necessary.
  4.  
  5. Pack the oil pump with petroleum jelly and reassemble. By packing the oil pump, a vacuum will be created upon initial fire-up and allow oil pressure to build immediately.
  6.  
  7. Install the crankcase cover and water pump.
  8.  
  9. Install the oil strainer using a new O-ring, and oil pan using a new gasket. Tighten the oil pan bolts to 3-4 ft. lbs. (4-5 Nm).
  10.  
  11. Install the flywheel housing cover.
  12.  
  13. Install the camshaft sprockets, crankshaft sprocket, timing belt and related components.
  14.  
  15. Install the crankshaft pulley and bolt.
  16.  
  17. Install the alternator and connect the electrical connectors.
  18.  
  19. Install the oil level gauge, the oil level gauge guide and the level gauge guide seal.
  20.  
  21. Fill the engine with oil. Connect the negative battery cable.
  22.  
  23. Start the engine and allow it to reach operating temperature. Check for adequate oil pressure. Then, check for leaks.
  24.  
  25. Adjust the ignition timing as required.
  26.  

1.6L Engine

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Oil pump and components-1.6L engine

The oil pump can be removed with the engine in the vehicle. The oil pump is located on the front of the engine, and has the oil filter mounted on it. The pump and filter may be removed as an assembly.

  1. Place a drip pan below the oil pump assembly to catch any oil that may spill out during removal and installation.
  2.  
  3. Unfasten the 4 bolts which secure the oil pump to the engine.
  4.  
  5. Remove the pump, complete with the gasket and filter.
  6.  
  7. Remove the filter from the pump and disassemble the pump.
  8.  

To install:
  1. Wash the disassembled oil pump in solvent. Allow the parts to dry completely before assembling.
  2.  
  3. Check the outside diameter of the oil pump rotor shaft. If worn or damaged, replace it.
  4.  
  5. Check the gear and rotor. Drive gear outside diameter should be 1.1693-1.1709 in. (29.70-29.74mm). Rotor outside diameter should be 1.5957-1.5968 in. (40.53-40.56mm). If not within specification, replace as necessary.
  6.  
  7. Check the clearance between the pump drive gear and pump rotor. If clearance is greater than 0.008 in. (0.2mm), replace the drive gear and rotor as an assembly.
  8.  
  9. Check the side clearance between the pump case and pump rotor, and between the pump case and drive gear. If clearance is greater than 0.008 in. (0.2mm), replace the necessary components.
  10.  
  11. Lay a straightedge across the pump case and measure the clearance between the pump case and the rotor. If greater than 0.0098 in. (0.25mm), replace the necessary components.
  12.  
  13. Check the relief valve spring. Free-length should be 1.854 in. (47.1mm).
  14.  
  15. Check the bypass valve and spring in the same manner.
  16.  
  17. Install the oil filter on the pump boss.
  18.  
  19. Using new gaskets and O-rings, fit the pump to the crankcase and carefully engage the pump drive with the slot in the end of the camshaft. Be sure that the pump mounts flush to the block.
  20.  
  21. Secure the pump with the 4 mounting bolts.
  22.  
  23. Check the engine oil level and add oil, as necessary, to replace any that was lost.
  24.  

1.8L and 2.7L Engines

See Figures 3 and 4

Click image to see an enlarged view

Fig. Fig. 3: Oil pump and components-1.8L and 2.7L engines



Click image to see an enlarged view

Fig. Fig. 4: Checking the oil pump clearance

The engine oil pump is located at the front of the engine. The oil filter is attached to the oil pump.

  1. Disconnect the negative battery cable.
  2.  
  3. Place an oil pan under the crankcase, remove the drain plug and drain the oil from the crankcase.
  4.  
  5. Remove the left and right front timing belt covers.
  6.  
  7. Loosen the tensioner mounting bolts on the No. 1 cylinder.
  8.  
  9. Turn the tensioner to fully loosen the belt, then tighten the mounting bolts.
  10.  
  11. Using a piece of chalk, mark the rotating direction of the timing belt, then remove the belt from the vehicle.
  12.  
  13. Remove the oil pump-to-engine bolts and the oil pump along with the oil filter from the cylinder block.
  14.  
  15. Remove the oil pump's outer rotor from the cylinder block.
  16.  
  17. Disassemble the oil pump.
  18.  

To install:
  1. Wash the disassembled components in solvent.
  2.  
  3. Check the outside diameter of the inner rotor shaft. Shaft diameter should be 1.4035-1.4055 in. (35.65-35.70mm).
  4.  
  5. Check the outside diameter of the outer rotor. Diameter should be 1.9665-1.9685 in. (49.95-50.00mm).
  6.  
  7. Check the clearance between the outer rotor and the cylinder block rotor housing. If clearance is greater than 0.0087 in. (0.22mm), replace the rotor.
  8.  
  9. Measure the height of the case projection H1 plus the oil pump inner and outer rotors H2 .
  10.  
  11. Measure the depth of the rotor housing bore L in the cylinder block.
  12.  
  13. Calculate the side clearance C using the following equation: C = L - (H1 + H2). If the side clearance is greater than 0.00071 in. (0.18mm), replace the pump inner and outer rotors with oversized versions.
  14.  
  15. Using new gaskets and O-rings, assemble the oil pump. Tighten the oil pump pulley to 13-15 ft. lbs. (18-21 Nm). Tighten the by-pass spring plug to 23-27 ft. lbs. (31-37 Nm).
  16.  
  17. Install the oil pump on the cylinder block.
  18.  
  19. Install the timing belt and related components.
  20.  
  21. Fill the engine with oil. Connect the negative battery cable.
  22.  
  23. Start the engine and allow it to reach operating temperature. Check for adequate oil pressure. Check for leaks.
  24.  
  25. Adjust the ignition timing as required.
  26.  

2.2L Engine

See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Oil pump and components-2.2L and 2.5L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil into a suitable container.
  4.  
  5. Drain the coolant into a suitable separate container.
  6.  
  7. Remove the water pump. Refer to the water pump removal and installation procedure in this section for details.
  8.  
  9. Remove the oil pump mounting bolts.
  10.  
  11. Carefully pry the oil pump from the engine block.
  12.  


WARNING
Use extreme care not to damage the engine block or the oil pump during removal of the pump.

  1. Remove the front crankshaft seal.
  2.  

To install:
  1. Measure the tip clearance of the rotors. If clearance is greater than 0.0071 in. (0.18mm), replace the rotors.
  2.  
  3. Measure the clearance between the outer rotor and the cylinder block rotor housing. If clearance exceeds 0.0079 in. (0.20mm), replace the rotor.
  4.  
  5. Measure the side clearance between the oil pump inner rotor and the pump cover. If clearance exceeds 0.0047 in. (0.12mm), replace the rotor or pump body.
  6.  
  7. Install a new front oil seal on the pump cover using a driver.
  8.  
  9. Assemble the oil pump.
  10.  
  11. Install a new front crankshaft seal using installer 499587100 or equivalent.
  12.  
  13. Apply sealant and a new O-ring to the oil pump.
  14.  
  15. Install the oil pump and torque the bolts to 5 ft. lbs. (7 Nm).
  16.  
  17. Install the water pump.
  18.  
  19. Fill the crankcase to the proper level with the recommended oil.
  20.  
  21. Fill and bleed the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for leaks.
  26.  

2.5L Engine

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the engine oil into a separate container.
  8.  
  9. Remove the belt covers, timing belt and related parts.
  10.  
  11. Remove the belt tensioner bracket.
  12.  
  13. Remove the engine coolant pipe.
  14.  
  15. Remove the water pump assembly.
  16.  
  17. Remove the oil pump mounting bolts and pry the pump from the engine block.
  18.  

Use extreme care not to damage the engine block or the oil pump during removal of the pump.

To install:
  1. Install a new front seal to the oil pump.
  2.  
  3. Apply a continuous bead sealant to the mating surfaces of the oil pump.
  4.  
  5. Install a new O-ring to the oil pump.
  6.  
  7. Install the oil pump and torque the bolts to 56 inch lbs. (6.4 Nm).
  8.  
  9. Install the water pump.
  10.  
  11. Install the engine coolant pipe.
  12.  
  13. Install the belt tensioner bracket, timing belt and the covers.
  14.  
  15. Fill the engine to the proper level with the recommended oil and coolant.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Fill and bleed the cooling system.
  20.  

3.3L Engine

See Figure 6

Click image to see an enlarged view

Fig. Fig. 6: Oil pump and components-3.3L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil into a suitable container.
  6.  
  7. Remove the engine under covers.
  8.  
  9. Remove the bolts securing the power steering oil cooler pipe. DO NOT remove the pipe.
  10.  
  11. Remove the cooling fan assemblies.
  12.  
  13. Remove the drive belt cover and drive belt.
  14.  
  15. Remove the crank angle sensors.
  16.  
  17. Remove the crankshaft pulley.
  18.  
  19. Remove the timing belt, tensioners and tensioner brackets.
  20.  
  21. Remove the oil pump mounting bolts.
  22.  
  23. Separate the oil pump from the block by inserting a suitable prying tool between the pump and the block.
  24.  
  25. Remove the oil pump and gasket.
  26.  
  27. Remove the front seal from the oil pump.
  28.  

To install:
  1. Measure the tip clearance of the rotors. If clearance is greater than 0.0071 in. (0.18mm), replace the rotors.
  2.  
  3. Measure the clearance between the outer rotor and the cylinder block rotor housing. If clearance exceeds 0.0079 in. (0.20mm), replace the rotor.
  4.  
  5. Measure the side clearance between the oil pump inner rotor and the pump cover. If clearance exceeds 0.0047 in. (0.12mm), replace the rotor or pump body.
  6.  
  7. Install a new oil seal in the oil pump.
  8.  
  9. Clean all gasket surfaces completely.
  10.  
  11. Install the oil pump using a new gasket. Tighten the mounting bolts to 5 ft. lbs. (7 Nm).
  12.  
  13. Install the timing belt components.
  14.  
  15. Install the crankshaft pulley.
  16.  
  17. Install the crank angle sensors.
  18.  
  19. Install the drive belts and drive belt cover.
  20.  
  21. Install the cooling fan assembly.
  22.  
  23. Install the bolts securing the power steering oil cooler pipe.
  24.  
  25. Install the engine under covers.
  26.  
  27. Lower the vehicle.
  28.  
  29. Refill the crankcase with oil.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Start the vehicle and verify no oil leaks.
  34.  

 
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