Removal and Installation

OIL PAN (UPPER)

Removal and Installation


REMOVAL


WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1.Remove oil filter. Refer to "Removal and Installation" Removal and Installation.
2.Remove oil cooler. Refer to "Exploded View" Exploded View.
3.Move A/C compressor to the position without the hindrance for work. Refer to "Exploded View" Exploded View.
4.Remove oil level gauge and oil level gauge guide.
5.Remove oil pressure switch and oil temperature sensor if necessary.
6.Remove rear plate cover.
7.Remove protector A and protector B. Refer to "FRONT TUBE ASSEMBLY : Exploded View" Exploded View.
8.Remove front suspension rear cross member. Refer to "2WD : Exploded View" Exploded View (2WD models) or
"4WD : Exploded View" Exploded View (4WD models).
9.Remove steering gear assembly. Refer to "Exploded View" Exploded View.
10.Remove front final drive assembly. Refer to "Exploded View" .
11.Remove oil pan (lower). Refer to "Exploded View" Exploded View.
12.Remove oil strainer. Refer to "Exploded View" Exploded View.
13.Remove bolts fixing oil pan (upper) to transmission assembly.
14.Remove oil pan (upper) as per the following:





a.Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove.





NOTE:
Disregard No. 9, 16 when loosening.





b.Insert a suitable tool into the notch at oil pan (upper) (1) as shown.
- Pry off case by moving a suitable tool.






CAUTION:
Be careful not to damage the mating surfaces.
15.Remove O-ring from bottom of cylinder block and oil pump.
16.Remove oil pressure switch and oil temperature sensor, if necessary.

INSTALLATION


CAUTION:
Do not reuse O-rings.
1.Install oil pan (upper) as per the following:





a.Use a scraper (A) to remove old liquid gasket from mating surfaces.
- Also remove the old liquid gasket from mating surface of cylinder block.
- Remove old liquid gasket from the bolt holes and threads.

CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b.Install new O-rings on the bottom of cylinder block and oil pump.

CAUTION:
Do not reuse O-rings.
c.Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the cylinder block mating surfaces of oil pan (upper) to a limited portion as shown in the figure.










Use Genuine RTV silicone sealant or equivalent. Refer to "Recommended Chemical Products and Sealants" Recommended Chemical Products and Sealants.

CAUTION:
Attaching must be done within 5 minutes after coating.





d.Tighten mounting bolts in numerical order as shown in the figure.






CAUTION:
Install avoiding misalignment of O-rings.
NOTE:
Tighten mounting bolts No. 1 and 2 in two steps. The numerical order No. 9 and 16 shown second steps.
- There are four types of mounting bolts. Refer to the following for locating bolts.





e.Tighten transmission joint bolts.
f.Install rear plate cover.
2.Install oil strainer.
3.Install oil pan (lower). Refer to "Removal and Installation" Removal and Installation.
4.Install in the reverse order of removal.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.