Oil Pan: Service and Repair

Oil Pan





Special Tool(s)

Removal
1. Disconnect the battery ground cable.
2. Partially drain the radiator and disconnect the upper radiator hose at the radiator.
3. Remove the air cleaner outlet tube.





4. Remove the accelerator cable splash shield.





5. Disconnect the accelerator and speed control cables and return spring.





6. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.





7. Disconnect the PCV vacuum and coolant hoses.





8. Disconnect the following vacuum lines:
^ PCV
^ brake booster
^ engine sensor control wiring harness





9. Disconnect the vacuum line.





10. Disconnect the idle air control motor electrical connector and the bypass hose.





11. Disconnect the heater hose.





12. If equipped, disconnect the EGR transducer and the throttle position sensor connectors.





13. If equipped, disconnect the EGR transducer vacuum lines





14. If equipped, disconnect the Exhaust Gas Recirculation (EGR) valve and the exhaust manifold tube louver fitting.





15. If equipped, remove the EGR transducer bracket.





16. If equipped, remove the EGR valve to exhaust manifold tube.
^ Disconnect the upper fitting.
^ Remove the tube.





17. If equipped, disconnect the EGR valve vacuum line.

18. NOTE: The EGR valve is shown removed for clarity.





If equipped, disconnect the EGR solenoid electrical and vacuum harness.





19. NOTE: The idle air control valve is shown removed for clarity.

Remove the throttle body adapter:
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove the throttle body adapter gasket.
20. Remove the two screws at the top of the fan shroud and position the fan shroud toward the engine.
21. Remove the generator.





22. Install the Modular Engine Support Bracket on the engine using the generator mounting holes.
23. Raise and support the vehicle.





24. Remove the engine mount nuts.

25. CAUTION:
^ Damage to the TSS/OSS may occur and cause transmission or torque converter operational concerns if the transmission is raised prior to removing TSS/OSS.
^ Sensor bosses must be cleaned prior to removal and then plugged to prevent contamination from damaging internal components.

If the vehicle is equipped with Turbine Shaft Speed (TSS) and Output Shaft Sensors (OSS), remove the sensors and install plugs in the transmission.
27. Raise the engine using a floor crane attached to the support bracket.





28. Support the engine using the 3-Bar Engine Support by inserting the J-hook.
29. Raise and support the vehicle.
30. Drain the engine oil and remove the oil bypass filter.
31. Remove the dual converter Y-pipe.





32. Remove the flywheel inspection plate.





33. Install the (A) High Lift Transmission Jack with the (B) E4OD Transmission Jack Adapter to the (C) transmission.

34. CAUTION: Support the transmission on the oil pan rails only or internal transmission damage may occur.





Support the (C) transmission with a transmission jack (A) and the (B) jack adapter.
35. Remove the driveshaft.





36. Remove transmission mount nuts.
37. Raise the transmission.





38. Remove the bolts and partially lower the oil pan.





39. Remove the bolts retaining the oil pump screen cover and pickup tube. Remove the pickup tube and spacer and let them drop into the oil pan.
40. Remove the oil pan and the oil pan gasket from the rear of the engine.

41. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the mating surfaces and thoroughly clean the oil pan.

Installation

NOTE:
^ Clean and inspect the oil pump screen cover and tube mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.
^ The oil pump screen cover and tube must be in the oil pan when the oil pan is positioned in the vehicle. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.





2. Install the oil pump screen and pickup tube.
1. Install and tighten the spacer.
2. Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer.
3. Install and tighten the bolts.

3. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant where the front cover and rear crankshaft seal retainer fit to the engine block.

4. NOTE: Be sure to tighten the bolts in three stages.





Tighten the bolts in the sequence shown:
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.
5. Lower the transmission.





6. Install the transmission mount nuts.
7. Install the driveshaft.
8. Remove the High Lift Transmission Jack and the E4OD Transmission Jack Adapter from the transmission.





9. Reinstall the transmission pan-to-case bolts that were removed to install the E4OD Transmission Jack Adapter.
10. If the vehicle is equipped with Turbine Shaft Speed (TSS) and Output Shaft Sensors (OSS), remove the plugs and install the sensors in the transmission.
11. Install the flywheel inspection plate.
12. Install the dual converter Y-pipe.
13. Install the oil bypass filter.
14. Lower the vehicle.





15. Using a floor crane, remove the 3-Bar Engine Support.
16. Align the engine mount studs and lower the engine.
17. Remove the floor crane.
18. Raise and support the vehicle.





19. Install the engine mount nuts.
20. Lower the vehicle.





21. Remove the Modular Engine Support Bracket from the engine.
22. Install the generator.
23. Install the fan shroud.

24. NOTE: The idle air control valve is shown removed for clarity.





Install the throttle body adapter
^ Position a new throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install four bolts and tighten in two stages.
^ Stage 1: Tighten to 8 -10 Nm (71 - 88 inch lbs.).
^ Stage 2: Tighten an additional 85 - 95 degrees.

25. NOTE: The EGR valve is shown removed for clarity.





If equipped, connect the EGR solenoid electrical and vacuum harness.





26. If equipped, connect the-EGR valve vacuum line.





27. If equipped, install the EGR valve-to-exhaust manifold tube.
^ Hand-tighten the fittings.
^ Tighten the upper timing to 60 Nm (44 ft. lbs.).
^ Tighten the lower fitting to 60 Nm (44 ft. lbs.).





28. If equipped, install the EGR transducer bracket.
^ Position the bracket.
^ Install the bolts.





29. If equipped, connect the EGR transducer vacuum lines.





30. If equipped, connect the EGR transducer and the throttle position sensor connectors.





31. Connect the heater hose.





32. Connect the idle air control motor electrical connector and the bypass hose.





33. Connect the vacuum line.





34. Connect the following vacuum lines:
^ brake booster
^ engine sensor control wiring harness





35. Connect the PCV vacuum and coolant hoses.





36. Install the accelerator cable bracket.
^ Position the bracket and cables.
^ Install the bolts.





37. Connect the accelerator and speed control cables and return spring.





38. Install the accelerator cable splash shield.
39. Install the air cleaner outlet tube.
40. Connect the battery ground cable.
41. Connect the upper radiator hose to the radiator.
42. Fill the engine with clean engine oil.
43. Fill and bleed the cooling system.