Suzuki Vitara, Grand Vitara, XL7 2000-06

Oil Pump

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Inspection



1.6L
  1. Check oil seal lip for fault or other damage. Replace as necessary.
  2.  
  3. Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
  4.  
  5. Check radial clearance between outer rotor and oil pump case, using thickness gauge. If clearance exceeds 0.0122 inch. (0.31 mm), replace outer rotor or case.
  6.  
  7. Check side clearance using straight edge and thickness gauge, clearance should not exceed 0.0059 inch. (0.15 mm).
  8.  

2.0L, 2.5L Engines
  1. Check outer rotor, inner rotor and oil pump cases for excessive wear or damage.
  2.  
  3. Check relief valve for excessive wear or damage.
    NOTE
    If any repair is required on outer rotor, inner rotor and oil pump cases, replace them as an assembly.

  4.  
  5. Measure free length and tension of oil relief spring.

    Click image to see an enlarged view

    Fig. Measuring spring length and tension

  6.  
  7. Measure clearance of oil pump rotor and oil pump case.
  8.  
  9. Check radial clearance between outer rotor and oil pump case, using thickness gauge.
  10.  
  11. If clearance exceeds its limit of 0.0059 inch. (0.15 mm), replace outer rotor or case.
  12.  
  13. Using straightedge and thickness gauge, measure side clearance.
  14.  
  15. Side clearance limit is 0.0043 inch. (0.11 mm).
  16.  

2.7L Engine
  1. Check outer rotor, inner rotor and oil pump cases for excessive wear or damage.
  2.  
  3. Check relief valve for excessive wear or damage.
  4.  
  5. Measure free length and tension of oil relief spring.
  6.  
  7. Measure clearance of oil pump rotor and oil pump case using thickness gauge.
  8.  
  9. Check radial clearance between outer rotor and case, using thickness gauge.
  10.  
  11. If clearance exceeds 0.0075 inch. (0.19 mm), replace oil pump assembly.
  12.  
  13. Using straightedge and thickness gauge, measure side clearance. If clearance exceeds 0.0043 inch. (0.11 mm), replace oil pump assembly.

    Click image to see an enlarged view

    Fig. Oil pump side clearance measurement

  14.  

Removal & Installation



1.6L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The oil pump bolts are different lengths. Note their location for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Alternator and bracket
     
    A/C compressor and bracket, if equipped
     
    Oil pan and oil pump pickup tube
     
    Crankshaft timing sprocket
     
    Oil pump
     



    Click image to see an enlarged view

    Fig. Oil pump housing short (1) and long bolt (2) locations-1.6L engines

  8.  

To install:

  1. Install or connect the following:

    Oil pump with a new gasket. Tighten the bolts to 97 inch lbs. (11 Nm).
     
    Crankshaft timing sprocket. Tighten the bolt to 94 ft. lbs. (130 Nm).
     
    Oil pan and oil pump pickup tube
     
    A/C compressor and bracket, if equipped
     
    Alternator and bracket
     
    Timing belt
     
    Front cover
     
    Crankshaft pulley. Tighten the bolts to 12 ft. lbs. (16 Nm).
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump housing-1.6L engines

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The oil pump bolts are different lengths. Note their location for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Timing belt
     
    Alternator and bracket
     
    A/C compressor and bracket, if equipped
     
    Oil pan and oil pump pickup tube
     
    Crankshaft timing sprocket
     
    Oil pump
     



    Click image to see an enlarged view

    Fig. Oil pump housing short (1) and long bolt (2) locations-1.6L engines

  8.  

To install:

  1. Install or connect the following:

    Oil pump with a new gasket. Tighten the bolts to 97 inch lbs. (11 Nm).
     
    Crankshaft timing sprocket. Tighten the bolt to 94 ft. lbs. (130 Nm).
     
    Oil pan and oil pump pickup tube
     
    A/C compressor and bracket, if equipped
     
    Alternator and bracket
     
    Timing belt
     
    Front cover
     
    Crankshaft pulley. Tighten the bolts to 12 ft. lbs. (16 Nm).
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump housing-1.6L engines

  6.  

1.8L And 2.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Do not remove the sprocket from the oil pump. Damage to the oil pump center shaft and abnormal pump operation may result.



    Negative battery cable
     
    Oil pan and pickup tube
     
    Oil pump sprocket cover
     
    Oil pump
     

  6.  

To install:

  1. Install or connect the following:

    Oil pump. Tighten the bolts to 20 ft. lbs. (27 Nm).
     
    Oil pump sprocket cover. Tighten the bolts to 108 inch lbs. (12 Nm).
     
    Oil pan and pickup tube
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of oil pump-1.8L, 2.0L and 2.5L engines

  6.  

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:
    WARNING
    Do not remove the sprocket from the oil pump. Damage to the oil pump center shaft and abnormal pump operation may result.



    Negative battery cable
     
    Oil pan and pickup tube
     
    Oil pump sprocket cover
     
    Oil pump
     

  6.  

To install:

  1. Install or connect the following:

    Oil pump. Tighten the bolts to 20 ft. lbs. (27 Nm).
     
    Oil pump sprocket cover. Tighten the bolts to 108 inch lbs. (12 Nm).
     
    Oil pan and pickup tube
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of oil pump-2.0L and 2.5L engines

  6.  

2.5L, 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    WARNING
    Do not remove the sprocket from the oil pump. Damage to the oil pump center shaft and abnormal pump operation may result.



    Negative battery cable
     
    Accessory drive belts
     
    Intake manifold
     
    Oil pan and oil pickup tube
     
    Front cover
     
    Oil pump chain guide
     
    Oil pump
     

  8.  

To install:

  1. Install or connect the following:

    Oil pump. Tighten the bolts to 20 ft. lbs. (27 Nm).
     
    Oil pump chain guide. Tighten the bolts to 97 inch lbs. (11 Nm).
     
    Front cover
     
    Oil pan and oil pickup tube
     
    Intake manifold
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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