Oil Pan - Removal

Oil Pan









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Remove the engine from the vehicle. For additional information, refer to Engine Engine - Removal.

2. Remove the 8 bolts and the flywheel.





3. Remove the crankshaft sensor ring.





4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

Mount the engine on an engine stand.

5. Remove the nut and the A/C tube from the compressor.
- Discard the O-ring seal and gasket seal.





6. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.





7. If equipped, remove the heat shield and disconnect the block heater electrical connector.
- Detach all of the engine block heater harness retainers and remove the harness.





8. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.





9. Disconnect the brake vacuum tube from the intake manifold.





10. Disconnect the 2 quick connect couplings and remove the PCV tube. For additional information, refer to Fuel System - General Information Service and Repair.





11. Disconnect the LH turbocharger bypass valve electrical connector.





12. NOTE: Index-mark the hoses for installation.

Remove the turbocharger wastegate regulating valve hoses from the RH CAC tube and turbocharger wastegate regulating valve.





13. Loosen the clamp and remove the LH turbocharger intake tube from the LH turbocharger.





14. Remove the 2 bolts and the LH turbocharger oil return tube from the turbocharger.
- Remove and discard the gasket.





15. Remove the LH turbocharger oil return tube from the oil pan.
- Discard the 2 O-ring seals.





16. Disconnect the RH turbocharger bypass valve electrical connector.





17. Loosen the clamp and remove the RH CAC tube from the RH turbocharger.





18. Loosen the clamp and remove the RH turbocharger intake pipe from the RH turbocharger.





19. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the nut from the RH valve cover stud bolt for the RH turbocharger intake tube.





20. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

Remove the RH CAC tube nut from the intake manifold and remove the RH CAC tube and turbocharger intake tube as an assembly.





21. Remove the noise insulator shield for the fuel injection pump and disconnect the electrical connector.





22. Disconnect the Throttle Position (TP) and electronic Throttle Body (TB) electrical connectors.





23. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.





24. Disconnect the Engine Oil Pressure (EOP) electrical connector.
- Detach the wiring harness retainer from the block.





25. Disconnect the 3 LH ignition coil-on-plug electrical connectors.





26. Remove the lower radiator hose from the thermostat housing.





27. Remove the engine cover mounting stud from the LH valve cover stud bolt.





28. Detach all the wiring harness retainers from the LH valve cover and stud bolts.

29. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.





30. Remove the oil level indicator.





31. Detach and disconnect the 2 fuel injector wiring harness electrical connectors.





32. Disconnect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.





33. Disconnect the turbocharger wastegate regulating valve electrical connector.





34. Detach the 2 wire harness-to-intake manifold retainers.





35. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.





36. Disconnect the 2 turbocharger coolant hoses from the intake manifold.





37. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

Remove the 12 bolts and the intake manifold.

- Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.

- Clean and inspect all sealing surfaces.





38. Disconnect the RH VCT solenoid electrical connector and detach the 2 wiring harness retainers.





39. Disconnect the 3 RH ignition coil-on-plug electrical connectors.





40. Detach all the wiring harness retainers from the RH valve cover and stud bolts.

41. Remove the nut for the high pressure fuel tube.





42. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.

Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails.

- Remove the high pressure fuel tube assembly.





43. Remove the 2 bolts and the fuel injection pump.





44. Remove the fuel injection pump mounting plate.





45. NOTE: Valve cover is removed for clarity.

Remove the fuel injection pump roller tappet.

- Inspect the fuel injection pump roller tappet. For additional information, refer to Fuel Charging and Controls Fuel Injection Pump Roller Tappet Inspection





46. Remove the 3 bolts and the 3 LH ignition coil-on-plugs.





47. Remove the 3 bolts and the 3 RH ignition coil-on-plugs.





48. Loosen the 10 stud bolts and remove the LH valve cover.
- Discard the gasket.





49. Loosen the 11 stud bolts and remove the RH valve cover.
- Discard the gasket.





50. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.

Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).





51. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.





52. Remove the 3 bolts and the accessory drive belt tensioner.





53. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.





54. Using the 3 Jaw Puller, remove the crankshaft pulley.





55. Using the Oil Seal Remover, remove and discard the crankshaft front seal.





56. Remove the stud bolt and Heated Oxygen Sensor (HO2S) connector bracket from the engine front cover.





57. NOTE: Only use hand tools to remove the studs.

Remove the 2 engine mount studs.





58. Remove the 3 bolts and the engine mount bracket.





59. Remove the 22 engine front cover bolts.





60. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.





61. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.

- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

62. NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan.

Remove the A/C compressor nut, bracket and the stud.





63. Remove the 16 oil pan bolts.





64. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan.
- Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
- Remove the oil pan.





65. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover and oil pan using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.

- Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.

66. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTICE: Do not use wire brushes, power abrasive discs or 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder block in the following sequence.

1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.