Chrysler 4663589 Pump, Oil

The oil pump pressure relief valve can be serviced without removing the oil pan and oil pick-up tube. Begin by disconnecting the negative battery cable from the ground stud on the left shock tower. Next, remove the oil pan and pick-up tube assembly, followed by the timing belt and crankshaft sprocket. For 2.4L engines, remove the oil filter. Detach the oil pump assembly from the engine, taking care to gently tap it with a soft-faced hammer if it does not come off by hand. Unscrew the mounting screws to remove the rotor assembly cover from the oil pump housing, and carefully withdraw the inner and outer rotors, ensuring no damage occurs as close tolerances are critical for correct oil pressure. Use a hammer and brass drift to remove and discard the crankshaft front seal from the oil pump housing, and also remove and discard the O-ring seal from the oil pump housing discharge port. Disassemble the relief valve assembly, noting the installation of the relief valve piston, and remove the cap bolt, washer, spring, and relief valve. Clean all components and inspect for excessive wear or damage, particularly the oil pressure relief valve piston sliding surface and valve spring, replacing them as a set if damaged. Measure the relief valve spring free length and compare it to the specified dimensions, replacing it if out of tolerance by more than 1/8 of an inch. Check the oil pump rotor dimensions and clearances with a micrometer or vernier calipers and a feeler gauge, replacing both rotors if any dimension is out of tolerance. Lubricate the relief valve piston, piston bore, and spring with clean engine oil, then install the relief valve piston with the grooved end first, followed by the spring and cap bolt, tightening the cap bolt to the specified torque. Lubricate the oil pump rotor recess and both rotors with clean engine oil, install them in the body, and fill the rotor cavity with clean engine oil before installing the cover and tightening the cover screws. Install a new O-ring in the oil discharge passage, apply anaerobic sealant to the oil pump body sealing surface, and position the pump assembly on the block, aligning the inner rotor and crankshaft drive flats, then tighten the oil pump attaching bolts. Install the new crankshaft front seal in the oil pump housing, followed by the crankshaft sprocket and timing belt. Reinstall the oil pump pick-up tube assembly and oil pan, then install a new oil filter. Lower the vehicle and fill the crankcase with the proper quantity and grade of oil. Finally, connect the negative battery cable to the ground stud on the left shock tower, and after the sealant has cured according to the manufacturer's directions, start the engine and check for leaks.

To remove the oil pump assembly, first disconnect the negative battery cable from the ground stud on the left shock tower, then raise the vehicle and support it securely on jackstands. Remove the drivebelts, timing belt, crankshaft sprocket, and Woodruff key, followed by the oil pan. If equipped, take off the air conditioning compressor bracket and position it out of the way. Detach the oil pump assembly from the engine, tapping gently with a soft-faced hammer if necessary. Remove and discard the oil filter passage O-ring seals, then take off the oil pump rotor cover. New rotors have arrows for alignment during installation; if not visible, match-mark them for correct positioning. Carefully remove the inner and outer rotors, ensuring no damage occurs. Drive out the crankshaft front seal from the oil pump housing and discard it. Disassemble the oil pressure relief valve assembly, noting the installation orientation of the relief valve piston. Clean all gasket sealing surfaces thoroughly, removing old gasket material and checking for distortion. Inspect all oil pump components for wear or damage, replacing as needed, and ensure the oil pressure relief valve piston and spring are also in good condition. Install the rotors into the pump housing with match-marks aligned, checking clearances with precision tools. Lubricate the relief valve piston, bore, and spring with clean engine oil, then install them in the original orientation. Lubricate the oil pump rotor recess and rotors, fill the rotor cavity with clean engine oil, and install the cover, tightening the screws to the specified torque. Install new O-ring seals in the oil pump passages, applying grease if necessary to hold them in place. Install the new crankshaft front seal into the oil pump housing, then apply anaerobic sealant to the oil pump body sealing surface and position the pump assembly on the block, aligning the inner rotor and crankshaft drive flats before installing the mounting bolts. If applicable, reinstall the air conditioning bracket, tighten the oil pump attaching bolts, and then install the Woodruff key, crankshaft timing belt sprocket, and timing belt. Reattach the oil pan and, if necessary, install a new oil filter. Follow the reverse order of removal for the remaining installation steps, lower the vehicle, fill the crankcase with the appropriate oil, reconnect the negative battery cable, and after the sealant has cured, start the engine and check for leaks.