Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Oil Pump

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REMOVAL & INSTALLATION



1.3L and 1.6L Engines

See Figures 1 through 27

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt and tensioner.
  4.  
  5. Remove the alternator and mounting bracket.
  6.  



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Fig. Fig. 1: Exploded view of the oil pump housing used on 1.3L and 1.6L engines



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Fig. Fig. 2: To remove the oil pump, remove the timing belt, then loosen the P/S pump bracket bolts ...



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Fig. Fig. 3: ... and remove the bracket from the engine



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Fig. Fig. 4: Prevent the crankshaft from turning by installing a holding tool on the flywheel ...



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Fig. Fig. 5: ... or you can use a large prybar to hold the flywheel steady



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Fig. Fig. 6: To use the prybar, insert it in the transmission case groove (arrow) and between two flywheel teeth

If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

  1. If equipped, remove the air conditioning compressor bracket bolts and support the compressor out of the way. Do NOT disconnect any of the A/C refrigerant lines.
  2.  
  3. Apply the parking brake and block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  


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. Drain the engine and front differential oil.
  2.  
  3. Remove the lower transmission (clutch or torque converter) inspection cover.
  4.  



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Fig. Fig. 7: With the crankshaft secured, loosen the timing belt sprocket retaining bolt ...



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Fig. Fig. 8: ... then slide the sprocket ...



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Fig. Fig. 9: ... and the timing belt guide off of the crankshaft



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Fig. Fig. 10: Loosen all 7 oil pump housing mounting bolts ...



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Fig. Fig. 11: ... then separate the oil pump housing from the engine block

  1. Remove the crankshaft timing belt sprocket by loosening the center bolt, while preventing the crankshaft from rotating. To hold the crankshaft from turning, you can use Suzuki Tool 09257-56010 (or equivalent), or a large prybar inserted in the transmission housing slot and the flywheel teeth (also shown in the accompanying photographs).
  2.  
  3. Remove the oil pan and oil pump pick-up.
  4.  
  5. Loosen the seven mounting bolts, and remove the oil pump housing. If the housing is difficult to separate from the engine block, use a small prytool against one of the mounting bolt bosses-do NOT slide the prybar between the oil pump housing and engine block mating surfaces.
  6.  
  7. If the oil pump is to be inspected, disassemble and inspect it as follows:
    1. Remove the oil level dipstick tube bracket bolt, then pull the dipstick and tube out of the oil pump housing.
    2.  
    3. Remove the oil pump rotor plate by loosening the five retaining screws. The rotor plate retaining screws can be difficult to remove, be sure not to strip the Philips grooves in the heads of the screws, otherwise the screw will need to be drilled out of the housing.
    4.  
    5. Remove the outer and inner rotors from the housing.
    6.  
    7. Without scratching the oil seal bore surface, use a small punch to drive the oil seal, or a seal removal tool to pry the oil seal, from the housing.
    8.  
    9. Remove the oil pressure relief retaining snap-ring from the housing bore, then remove the retainer cap, spring and piston from the housing. Ensure that the piston bore is thoroughly cleaned when cleaning the housing.
    10.  
    11. Clean the oil pump housing, rotors and pressure regulating components until free of all dirt and oil.
    12.  
    13. Install the inner and outer rotors in the oil housing bore. The outer rotor should be installed so that the small dot, marked on one of its faces, points away from the housing. The inner rotor will only fit in the housing in one orientation: the raised ring must face away from the housing.

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      Fig. Fig. 12: If the oil pump is to be inspected, remove the 5 cover screws and remove the cover from the housing



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      Fig. Fig. 13: The screws can be difficult to remove-using a screwdriver with wrenchable flats will increase leverage



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      Fig. Fig. 14: Remove the oil pressure relief retaining snapring ...



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      Fig. Fig. 15: ... then extract the retainer cap (A), spring (B) and piston (C) from the housing (D)



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      Fig. Fig. 16: Use a seal prytool to remove the old oil seal from its bore



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      Fig. Fig. 17: Use feeler gauges to measure the outer rotor-to-bore wall clearance-if the clearance is out of specifications, the oil pump components must be replaced



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      Fig. Fig. 18: Using a straightedge and feeler gauges, also measure the amount of rotor side clearance

    14.  
    15. Using feeler gauges, measure the clearance between the outer rotor and bore wall. Then, using a straightedge spanning the oil pump housing and rotors, measure the clearance between the edge of the straightedge and oil pump rotors. Compare your findings with the engine rebuilding specification charts at the end of this section.
    16.  
    17. If the measurements were not within the specified ranges, or one or more oil pump components shows evidence of excessive wear or damage, the oil pump components should be replaced.To install:
    18.  

  8.  
  9. If the oil pump was disassembled for inspection, assemble it as follows:
    1. Using an oil seal installer, or an aptly-sized socket, drive the new oil seal into the seal bore. Ensure that the seal is driven in straight and is fully seated in the housing.

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      Fig. Fig. 19: Use an oil seal installer, or a large socket, and a hammer to drive the new seal into the housing



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      Fig. Fig. 20: Drive the oil seal into the housing until its outer edge is flush with the oil pump housing surface



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      Fig. Fig. 21: When installing the rotors, ensure that the dot (arrow) on the outer rotor faces away from the housing

    2.  
    3. Apply a thin coat of clean engine oil to the oil pump rotors, the oil seal lip, the inside surfaces of the oil pump housing (including the regulator bore), and to the oil pressure piston (relief valve).
    4.  
    5. Install the relief valve, the spring, the retainer cap and a new snap-ring in the housing bore.
    6.  
    7. Install the inner and outer pump rotors in the housing.
    8.  
    9. Position the rotor plate on the housing, then install and tighten the five retaining screws securely. After tightening the screws, ensure that the oil pump rotors spin smoothly by hand.
    10.  
    11. Install a new oil level dipstick tube seal in the housing, then insert the end of the tube in the housing. Install the tube bracket bolt and tighten it securely.
    12.  

  10.  
  11. Ensure the two oil pump locating pins are installed in the engine block, then install a new oil pump housing-to-engine block gasket.
  12.  
  13. Install Suzuki Tool 09256-11510, or its equivalent, onto the crankshaft. Apply a thin coating of clean engine oil onto the outer surfaces of the tool. This tool will prevent the new oil seal lip from being damaged when the oil pump housing is installed on the engine block.
  14.  
  15. Ensure the flats on the inside of the oil pump bore are aligned with the flats on the crankshaft, then carefully slide the oil pump housing onto the crankshaft and against the engine block until flush. Install the oil pump housing mounting bolts and tighten them to 30 inch lbs. (11 Nm). When installing the oil pump mounting bolts, be sure to install the shorter oil pump bolts as indicated in the accompanying illustration. The three other bolts are slightly longer and should be installed in the lower holes.
  16.  



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Fig. Fig. 22: Install the special tool over the crankshaft so that the new oil seal lip will not be damaged when the oil pump housing is installed



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Fig. Fig. 23: Be sure to install the short (1) and the long mounting bolts (2) in the correct positions during oil pump housing installation



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Fig. Fig. 24: Install a new rubber seal between the oil pump and the water pump before installing the timing belt outer cover



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Fig. Fig. 25: After installing the oil pump housing, cut any protruding gasket material off flush with the oil pan mating surface

  1. Install a new rubber seal between the oil pump and the water pump.
  2.  
  3. Inspect the lower oil pump edge to ensure that the gasket is not protruding past the surface. If the gasket protrudes from the oil pump, cut it flush with a sharp knife.
  4.  
  5. Install the timing belt guide, key and crankshaft timing belt sprocket.
  6.  
  7. Install the timing belt, tensioner, oil pump pick-up, oil pan and all other related components.
  8.  
  9. On 4-wheel drive models, install the front differential unit.
  10.  


WARNING
Operating the engine without the proper amount and type of engine oil can result in severe engine damage.

  1. Adjust the valve lash on all valves, then refill the engine with the proper type and amount of engine oil.
  2.  
  3. If equipped, refill the front differential with the proper type and amount of lubricant.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. After filling the engine with engine oil, start the vehicle and inspect the oil pressure as follows:
    1. Remove the oil pressure switch from the engine block.
    2.  
    3. Install an oil pressure gauge in the oil pressure switch threaded hole. Ensure that your oil pressure gauge hose is equipped with the same thread pitch and size as the oil pressure switch, otherwise damage to the oil pressure switch hole will result.
    4.  
    5. Start the engine and allow it to warm up to normal operating temperature.
    6.  
    7. Place the transmission in Neutral (manual models) or Park (automatic models), apply the parking brake and block the drive wheels.
    8.  
    9. Raise the engine speed to 3000 rpm and read the value indicated by the oil pressure gauge. The oil pressure should match the values presented in the engine rebuilding specifications charts at the end of this section. If the oil pressure is not as indicated, there is a defect in the engine lubrication system.
    10.  
    11. After inspecting the oil pressure, stop the engine and remove the oil pressure gauge.
    12.  
    13. Install the oil pressure switch, making sure to wrap its threads with Teflon® sealing tape. Tighten the switch to 124 inch lbs. (14 Nm). Cut off any exposed Teflon® tape.
    14.  



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    Fig. Fig. 26: To test the engine oil pressure, remove the oil pressure switch (arrow), which is threaded into the engine block, next to the exhaust manifold



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    Fig. Fig. 27: Install a pressure gauge in the oil pressure switch hole

  8.  
  9. Start the engine and inspect the oil pan and pressure switch for leaks.
  10.  

1.8L Engine

See Figures 28, 29, 30, 31, 32, 33, 34, 35 and 36

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the oil pan and oil pump pick-up.
  4.  
  5. Remove the oil pump sprocket cover mounting bolts, then separate the cover from the engine.
  6.  

When separating the pump from the engine, do not loose the small locating dowels; they will be needed upon installation.

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Fig. Fig. 28: Exploded view of oil pump and sprocket cover mounting



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Fig. Fig. 29: After removing the oil pan, remove the sprocket cover to gain access to the oil pump

  1. Remove the oil pump mounting bolts, and remove the oil pump from the lower crankcase. If the oil pump is difficult to separate from the engine, tap it lightly with a soft-faced mallet until it works loose.
  2.  


WARNING
Do NOT remove the sprocket from the oil pump, otherwise damage to the oil pump center shaft and abnormal pump operation may be the result.

  1. Clean the oil pump-to-engine mating surface thoroughly.
  2.  
  3. If the oil pump is to be inspected, disassemble and inspect it as follows:
    1. Separate the two oil pump case halves by loosening the five attaching screws.
    2.  
    3. Remove the outer and inner rotors from the housing.

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      Fig. Fig. 30: Exploded view of the oil pump assembly



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      Fig. Fig. 31: If inspecting the oil pump, use feeler gauges to measure the outer rotor-to-pump bore ...



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      Fig. Fig. 32: ... and the rotor side clearance-if the clearances measured are not within the specified ranges, replace the oil pump

    4.  
    5. Remove the oil pressure relief retainer from the housing, then remove the spring and piston (relief valve) from the housing. Ensure that the piston bore is thoroughly cleaned when cleaning the housing.
    6.  
    7. Clean the oil pump housing, rotors and pressure relief components until free of all dirt and oil.
    8.  
    9. Install the inner and outer rotors in the oil housing bore.
    10.  
    11. Using feeler gauges, measure the clearance between the outer rotor and bore wall. Then, using a straightedge spanning the oil pump housing and rotors, measure the clearance between the edge of the straightedge and oil pump rotors. Compare your findings with the engine rebuilding specification charts at the end of this section.
    12.  
    13. If the measurements were not within the specified ranges, or one or more oil pump components shows evidence of excessive wear or damage, the oil pump should be replaced.To install:
    14.  

  4.  
  5. If the oil pump was disassembled for inspection, assemble it as follows:
    1. Apply a thin coat of clean engine oil to the oil pump rotors, the inside surfaces of the oil pump housing (including the relief bore), and to the oil pressure piston (relief valve).
    2.  
    3. Install the relief valve, the spring, and the retainer in the housing bore.
    4.  
    5. Install the inner and outer pump rotors in the housing.

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      Fig. Fig. 33: Before assembling the two oil pump case halves, ensure that the locating (case) pins are installed

    6.  
    7. Assemble the two oil pump halves, then install and tighten the five retaining screws to 106 inch lbs. (12 Nm). After tightening the screws, ensure that the oil pump gear spins smoothly by hand.When installing the oil pump, do not allow the locating dowels to fall out of position.
    8.  

  6.  
  7. Ensure the locating dowels are installed in the pump, then position the oil pump sprocket in the drive chain and the pump housing against the lower crankcase. Install and tighten the mounting bolts to 110 inch lbs. (20 Nm).
  8.  
  9. Install the oil pump sprocket cover and tighten the mounting bolts to 30 inch lbs. (11 Nm).
  10.  
  11. Install the oil pump pick-up and oil pan.
  12.  
  13. Refill the engine with the proper type and amount of engine oil.
  14.  


WARNING
Operating the engine without the proper amount and type of engine oil can result in severe engine damage.

  1. Connect the negative battery cable.
  2.  
  3. After filling the engine with engine oil, start the vehicle and inspect the oil pressure as follows:
    1. Remove the oil pressure switch from the engine block.
    2.  
    3. Install an oil pressure gauge in the oil pressure switch threaded hole. Ensure that your oil pressure gauge hose is equipped with the same threads as the oil pressure switch, otherwise damage to the oil pressure switch hole will result.

      Click image to see an enlarged view

      Fig. Fig. 34: To inspect the oil pump output pressure, remove the oil pressure sender, located near the flywheel on the left-hand side of the engine ...



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      Fig. Fig. 35: ... then install an oil pressure gauge-run the engine at 4000 rpm and observe the gauge for oil pump output pressure



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      Fig. Fig. 36: Wrap the oil pressure sender threads with sealing tape prior to installation

    4.  
    5. Start the engine and allow it to warm up to normal operating temperature.
    6.  
    7. Place the transmission in Neutral (manual models) or Park (automatic models), apply the parking brake and block the drive wheels.
    8.  
    9. Raise the engine speed to 4000 rpm and read the value indicated by the oil pressure gauge. The oil pressure should be 55-66 psi (323-43 kPa). If the oil pressure is not as indicated, there is a defect in the engine lubrication system.
    10.  
    11. After inspecting the oil pressure, stop the engine and remove the oil pressure gauge.
    12.  
    13. Install the oil pressure switch, making sure to wrap its threads with Teflon® sealing tape. Tighten the switch to 124 inch lbs. (14 Nm). Cut off any exposed Teflon® tape.
    14.  
    15. Start the engine and inspect the oil pan and pressure switch for leaks.
    16.  

  4.  

OIL SEAL REPLACEMENT



See Figure 37

This procedure only applies to the 1.3L and 1.6L engines; the 1.8L engine oil pump does not use an oil seal. This procedure is also written for oil seal replacement only. If you must remove the oil pump for other service, the procedures presented under oil pump removal and installation include oil seal replacement.

  1. Remove the timing belt, crankshaft sprocket and belt guide.
  2.  
  3. Using a small prytool, carefully pry the old oil seal out of the oil pump housing bore. Take care not to scratch the oil pump housing bore, otherwise oil leakage may occur. Wrapping a piece of tape around the end of the prytool may help reduce the change of scoring the bore by covering any sharp corners on the tool.
  4.  
  5. Clean the oil pump housing bore and the crankshaft.
  6.  
  7. If the oil seal is being removed because of oil leakage, inspect the crankshaft surface where the oil seal contacts it. If there is a wear groove on the crankshaft, a new oil seal will probably not cure the oil leak. Before removing the crankshaft and replacing it, attempt to repair it by installing a metal sleeve, designed just for this problem, over the crankshaft end. The crankshaft sleeve will present a new, flat surface for the new oil seal to seal against. Crankshaft sleeves are usually available from automotive parts stores.
  8.  



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Fig. Fig. 37: Using a deep socket and a hammer, drive the oil seal into the housing until its outer edge is flush with the oil pump housing surface

  1. Apply a thin coat of clean engine oil to the oil seal lip, then slide the oil seal over the crankshaft and into position against the oil pump housing. Use a deep socket, which is the same diameter as the oil seal, and a hammer to drive the oil seal into the housing. Drive the new seal into the housing only until the outer seal edge is flush with the oil pump housing surface.
  2.  
  3. Install the timing belt guide, crankshaft sprocket, timing belt, and all other related components.
  4.  
  5. Once the engine is reassembled, start it and check for oil leaks.
  6.  

 
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