Removal And Installation

OIL PAN AND OIL STRAINER


Removal and Installation


REMOVAL (LOWER)

WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove rear engine undercover.
2. Drain engine oil. Removal and Replacement.
3. Remove oil pan (lower) as follows:





a. Remove the oil pan (lower) bolts using power tool in reverse order as shown.





b. Insert Tool between the oil pan (lower) and the oil pan (upper).






CAUTION:
- Be careful not to damage the mating surfaces.
- Do not insert screwdriver, this will damage the mating surfaces.
NOTE:
Tap (1) Tool to insert it and then slide (2) it by tapping on the side of the Tool as shown.

INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.

INSTALLATION (LOWER)
1. Install oil pan (lower) as follows:





a. Use scraper to remove old liquid gasket from mating surfaces.
- Also remove old liquid gasket from mating surface of oil pan
(upper).
- Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.





b. Apply a continuous bead of liquid gasket using Tool to the oil pan (lower) as shown.






Use Genuine RTV Silicone Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants.
CAUTION:
Attaching should be done within 5 minutes after coating.
c. Install oil pan (lower).





- Tighten oil pan (lower) bolts in numerical order as shown.
2. Install oil pan drain plug. SEE Removal and Installation.
3. After 30 minutes fill with engine oil and inspect for leaks. Removal and Replacement.
CAUTION:
Do not fill the engine with oil for at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION
1. Start engine, and check for engine oil leaks.
2. Stop engine and wait for 10 minutes.
3. Check engine oil level. Procedures.

REMOVAL (UPPER)
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
CAUTION:
- Perform this procedure when engine is cold.
- Do not spill engine oil on drive belts.
- Do not spill engine coolant on drive belts.
1. Remove engine under cover (front). Service and Repair.
2. Drain engine coolant. Service and Repair.
3. Remove oil pan (lower). Refer to REMOVAL (LOWER).
4. Reposition the (RH) brake caliper aside and support with a suitable wire without disconnecting the front brake hose (4WD models). Removal And Installation.
5. Remove oil level gauge and oil level gauge guide.
6. Remove front final drive (4WD models). Front Final Drive R180A.
7. Remove front frame crossmember.
8. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way.
Power Steering Gear And Linkage.
9. Remove stabilizer bar brackets and position stabilizer bar out of the way. Front Suspension.
10. Disconnect A/T fluid cooler tube brackets and position out of the way (A/T models). Transmission Assembly, Transmission Assembly (4WD models).
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
11. Remove oil filter, if necessary. Service and Repair.
12. Disconnect oil cooler hoses. Remove oil cooler, if necessary. Removal And Installation.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
13. Remove oil cooler, if necessary. Removal And Installation
14. Disconnect oil pressure switch and remove.
15. Remove oil pan (lower).
16. Remove oil strainer.
17. Remove transmission joint bolts which pierce oil pan (upper). Transmission Assembly, "Removal and Installation
Transmission Assembly (2WD A/T models), Transmission Assembly, "Removal and Installation (4WD)" (4WD A/T models).
18. Remove rear cover plate.





19. Remove oil pan (upper) bolts with power tool in reverse order as shown.





- Insert Tool between oil pan (upper) and lower cylinder block.
Tap (1) Tool to insert it and then slide (2) it by tapping on the side as shown.






CAUTION:
Be careful not to damage mating surfaces.





20. Remove O-rings from bottom of lower cylinder block and oil pump.

INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.

INSTALLATION (UPPER)
1. Install oil pan (upper) as follows:





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

CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.





b. Install new O-rings on the bottom of lower cylinder block and oil pump.





c. Apply a continuous bead of liquid gasket using Tool to the lower cylinder block mating surfaces of oil pan (upper) as shown.






Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
- For bolt holes with Dark Triangle mark, apply liquid gasket outside the hole.
- Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diameter to area (A).
- Attaching should be done within 5 minutes after coating.
d. Install oil pan (upper).

CAUTION:
Install avoiding misalignment of both oil pan gaskets and O-rings.





- Tighten oil pan (upper) bolts in numerical order as shown.
- There are two types of bolts.






e. Tighten transmission joint bolts. Transmission Assembly (4WD M/T models), Transmission Assembly (2WD A/T models), Transmission Assembly (4WD A/T models).
2. Install oil strainer to oil pan (upper).
3. Installation of the remaining components is in the reverse order of removal.

CAUTION:
Do not fill the engine with oil for at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: