Oil Pan: Service and Repair

Removal
Engine removal is not required in this procedure.

WARNING:
- Make sure jacks and safety stands are placed properly.
- Apply the parking brake and block the rear wheels so the vehicle will not roll off stands while you are working under it.

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- Unplug the wiring connectors carefully while holding the connector portion to avoid damaging.
- Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses or interfere with other parts.

1. Loosen the idler pulley center nut and adjusting bolt, then remove the air conditioning (A/C) compressor belt.
2. Disconnect the power steering pressure (PSP) switch connector, then remove the power steering pump belt and pump.
3. Remove the left and right side exhaust manifold covers.
4. Raise the hoist to full height.
5. Remove the front tires/wheels and splash shield.
6. Remove the damper forks.
7. Disconnect the suspension lower arm ball joints with the special tool.
8. Remove the driveshafts and intermediate shaft.
9. Drain the differential oil. Reinstall the drain plug using a new washer.
10. Drain the engine oil. Reinstall the drain bolt using a new washer.
11. Disconnect the vehicle speed sensor (VSS) connector, then remove the VSS/power steering speed sensor. Do not disconnect the fluid hoses.





12. Remove the lower plate from the rear beam.
13. Remove the A/C compressor.
14. Attach the chain hoist to the engine.
15. Remove the left engine mount bracket.





16. Remove the right engine mount bracket.





17. Disconnect the vacuum hose, then remove the right engine mount.
18. Remove the left and right front engine mount bolts.





19. Remove the 36 mm sealing bolt.
20. Disconnect the extension shaft from the differential with the special tool.





21. Remove the differential mounting bolts and 26 mm shim, then remove the differential assembly.
22. Remove the stiffener.
23. Remove the drive plate cover.
24. Remove the oil pan.

Installation
Install the oil pan in the reverse order of removal:
- Always use new O-rings.
- Oil pan and cylinder block mating surface must be clean.





1. Apply liquid gasket to the cylinder block, then install the oil pan.

NOTE:
- Use liquid gasket, Part No. 08718-0001 or 08718-0003.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- Apply liquid gasket evenly, being careful to cover all the mating surface.
- Do not apply liquid gasket to O-ring grooves.
- To prevent oil leakage, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
- After assembly, wait at least 30 minutes before filing the engine with oil.





NOTE: Use new O-rings. Apply oil to the O-rings before installation.





2. Tighten the oil pan bolts.
3. install the differential assembly.
Select the appropriate 26 mm shim whenever the oil pan or the cylinder block is replaced. Refer to Differential for selection of the correct 26 mm shim.





4. Apply grease to the spline of the extension shaft, then install the new set ring with the open side facing up.








5. Install the extension shaft with the special tool.

NOTE: Make sure the extension shaft locks in place.

6. Fill the cavity with High Temp Urea Grease (P/N 08798-9002).





7. Reinstall the 36 mm sealing bolt and the secondary cover. Apply liquid gasket (P/N 08718-0001) to the sealing bolt threads.
8. Check the following after reassembly.
- Refill the differential with differential oil.
- Refill the engine with engine oil.
- Make sure the set rings on the driveshafts are completely inserted into the grooves of the differential or intermediate shaft.
- Adjust the A/C compressor belt tension.
- Adjust the P/S pump belt tension.