Mercury 3M4Z-6600-BA Pump Assembly - Oil

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Disconnect the negative cable from the battery and place the number one cylinder at top dead center (TDC) on the compression stroke. Remove the drivebelt and the drivebelt tensioner, then place a jack beneath the engine to support it, using a block of wood between the jack and oil pan for protection. Remove the damper from the right engine mount, unbolt the mount from the bracket, loosen the mount through-bolt, and pivot the mount away from the engine. Remove the timing belt cover, then pivot the engine mount back into position and reattach it to the engine, removing the jack afterward. Loosen the timing belt tensioner bolt, pry the tensioner toward the rear of the engine, and tighten the bolt to hold the tensioner in this position. Securely block the rear wheels to prevent rolling, jack up the front, and place it on jackstands, ensuring not to get under a vehicle supported only by a jack. Remove the splash shield from the passenger's side, the catalytic converter, the oil pan, and the oil filter. Remove the crankshaft damper and timing belt, along with the timing belt pulley and guide from the crankshaft, and the crankshaft position sensor. Unbolt the oil pump from the engine, take off the oil pump and gasket, and unbolt the screen and cover assembly from the pump. Remove and discard the crankshaft front oil seal from the pump, then carefully clean all traces of the old gasket from the pump, screen, and engine without scratching the mating surfaces. Lubricate the outer edge of a new crankshaft seal with light engine oil, install the seal, and lubricate the seal lip. To install the seal, place the oil pump on wood blocks and drive the new seal into place with a hammer and socket slightly smaller in diameter than the outer edge of the seal. Place the oil pump gasket on the pump, pour oil into the pump, rotate its shaft to prime it, and position the pump on the engine, using a small screwdriver through the oil pick-up hole to guide the pump drive gear onto the crankshaft. Install the oil pump mounting bolts and tighten them evenly, ensuring the oil pump gasket doesn't extend below the sealing surface on the cylinder block. Install the oil screen with a new gasket and tighten its bolts, then install the timing belt guide on the crankshaft with its flanged side away from the timing belt. The remainder of the installation follows the reverse order of removal steps. Fill the engine with oil, check its level, run the engine, and check for oil leaks.

There is no sub-assembly or internal inspections involved in servicing of the oil pump as a whole body. First of all it is necessary to siphon off the engine oil and unscrew the oil filter. For 1.6L and 2.0L models remove the boost pressure sensor that is connected to the turbocharger, disconnect the Charge Air Cooler inlet and outlet hoses and then remove the air conditioning compressor. For 1.5L and 1.6L engines the timing belt and crankshaft sprocket should be removed while for 2.0L, 2.3L and 2.5L a timing chain cover should be removed. In all models, drain the engine oil and also pull off the oil pan, and the oil pick-up tube which is secured by two mounting bolts. For 1.5L and 1.6L engines, it actually removes oil pump mounting bolts and separates it from the front of the engine block; oil pump gasket has to be replaced with a new one. In the course of performing the above for 2.0L, 2.3L and 2.5L engines, you will have to use a screwdriver to pry off the end of the spring in the oil pump drive chain tensioner from under the shouldered bolt after pulling out the two bolts to remove the tensioner before finally using a screwdriver to detach the chain from the oil pump sprocket. To do this remove the sprocket bolt using a suitable tool, after this remove the oil pump drive sprocket. Following the removal of the oil pump mounting bolt, you should encourage the pump. The process of installation is exactly the opposite to that of removal, and while reassembling the engine the mechanic has to make sure that all the gaskets are replaced with new ones, lightening the oil pump mounting bolts in a correct sequence for 1.5 and 1.6 versions, and tightening the oil pump mounting bolts for 2.0 and 2.3 and 2.5 versions. After fitting the new oil pan, replace the oil filter, and add fresh oil into the crankcase, inspect the vehicle's cluster for any oil warning lights if fitted after starting and warming up the vehicle.

It is easiest to remove the 2.0L engine oil pump with the engine removed; however, to remove the oil pump pressure relief valve you don't necessarily have to pull the engine from the vehicle. First, evacuation of the AC system is necessary, after that run the timing belt, crankshaft sprocket, and guide washer, remember the position of the guide washer. Subsequently, remove the oil pan and, after that, the bolts and the gasket of the oil pump pick-up tube. Take out the air conditioning compressor and its bracket then take out the timing belt tensioner. Loosen the bolts that hold the lower crankcase by using a ratchet wrench and then remove the lower crankcase by pulling it gently away from the engine block and the transaxle, if need be; retrieve any spacer washers and gasket and clean the two mating areas. Remove the pump from the engine block bolts and get rid of of the gasket, before washing the components. Look at the pump by removing the cover of the pump and rotors and see the extent of wear or damage of the part and install new ones if Needed. The oil pressure relief valve is conveniently located such that it can be dismantled while the pump remains intact, so that one may inspect it and then put it back together. During the reassembly keep the housing and all components well lubricated and fill the oil pump with fresh engine oil for it to begin pumping oil as soon as installed. Ensure that the pump is placed parallel to the crankshaft and make sure that it is positioned correctly fastening the bolts tightly. Replace oil pump housing and fit new seal then apply sealant to other joints so as to lift the lower crankcase and fixing it through the use of bolts. The lower crankcase should be properly positioned on the cylinder block before the bolts are tightened with reference to the stated sequence. The 2.3L engine has the oil pump located inside the engine block and thus requires engine dismantling for the pump to be serviced; it is a total loss unit. For the 2.5L engine, lift the vehicle, retract the timing chain cover and the oil pan and then, unbolt the pick-up tube and strainer of the oil pump on the engine. Relieve the tension on the oil pump drive chain tensioner and then undo the bolts holding the tensioner and carefully incline the chain off the sprocket for the oil pump and then remove the sprocket and the pump. Installation is the opposite of disassembly to guarantee perfect fixation of all the parts and components.

It is easiest to remove the 2.0L engine oil pump with the engine removed; however, to remove the oil pump pressure relief valve you don't necessarily have to pull the engine from the vehicle. First, evacuation of the AC system is necessary, after that run the timing belt, crankshaft sprocket, and guide washer, remember the position of the guide washer. Subsequently, remove the oil pan and, after that, the bolts and the gasket of the oil pump pick-up tube. Take out the air conditioning compressor and its bracket then take out the timing belt tensioner. Loosen the bolts that hold the lower crankcase by using a ratchet wrench and then remove the lower crankcase by pulling it gently away from the engine block and the transaxle, if need be; retrieve any spacer washers and gasket and clean the two mating areas. Remove the pump from the engine block bolts and get rid of of the gasket, before washing the components. Look at the pump by removing the cover of the pump and rotors and see the extent of wear or damage of the part and install new ones if Needed. The oil pressure relief valve is conveniently located such that it can be dismantled while the pump remains intact, so that one may inspect it and then put it back together. During the reassembly keep the housing and all components well lubricated and fill the oil pump with fresh engine oil for it to begin pumping oil as soon as installed. Ensure that the pump is placed parallel to the crankshaft and make sure that it is positioned correctly fastening the bolts tightly. Replace oil pump housing and fit new seal then apply sealant to other joints so as to lift the lower crankcase and fixing it through the use of bolts. The lower crankcase should be properly positioned on the cylinder block before the bolts are tightened with reference to the stated sequence. The 2.3L engine has the oil pump located inside the engine block and thus requires engine dismantling for the pump to be serviced; it is a total loss unit. For the 2.5L engine, lift the vehicle, retract the timing chain cover and the oil pan and then, unbolt the pick-up tube and strainer of the oil pump on the engine. Relieve the tension on the oil pump drive chain tensioner and then undo the bolts holding the tensioner and carefully incline the chain off the sprocket for the oil pump and then remove the sprocket and the pump. Installation is the opposite of disassembly to guarantee perfect fixation of all the parts and components.

Install the oil pump drive chain complete with the oil pump sprocket, aligning the flats on the oil pump driveshaft and oil pump sprocket, and tighten the retaining bolt to the specified torque setting while holding the oil pump drive sprocket to prevent it from turning.

Unbolt the pump from the cylinder block/crankcase, withdraw and discard the gasket, and remove the crankshaft right-hand oil seal.

On 3.5L engines, the procedure can only be done with the engine removed. In the steps below, it is assumed that the 3.5L engine has been removed; ignore the steps which don't apply.

10. Rotate the oil pump inner rotor so it aligns with the flats on the crankshaft. Install the oil pump over the crankshaft and fit it firmly against the cylinder block. 11. Install the oil pump bolts and tighten by hand until snug. Tighten the bolts gradually and evenly, in sequence, to the specified torque. 12. Install the remainder of the components in the reverse order of removal. 13. Fill the engine with fresh engine oil. Install a new oil filter. Refill the cooling system. 14. Start the engine and check for leaks.

4. Remove the oil pump cover from the oil pump body. 5. Note any identification marks on the rotors and withdraw the rotors from the pump body. 6. Thoroughly clean and dry the components. 7. Inspect the rotors for obvious wear or damage. If either rotor, the pump body, or the cover is scored or damaged, the complete oil pump assembly must be replaced. 8. If the oil pump components are in acceptable condition, dip the rotors in clean engine oil and install them into the pump body with any identification marks positioned as noted during disassembly. 9. Install the cover and tighten the screws securely.