Oil Pan: Service and Repair

Removal and Installation

REMOVAL

WARNING:
^ You should not remove the oil pan until the exhaust system and cooling system have completely cooled off.
^ When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly for safety. For engine slingers, refer to step 18 in "Removal"

CAUTION: When removing the upper oil pan from the engine, first remove the crankshaft position sensor (POS). Be careful not to damage sensor edges or signal plate teeth.

1. Remove the front RH wheel and tire with power tool.
2. Disconnect the battery negative terminal.
3. Remove the oil dipstick.
4. Drain the engine coolant.
5. Remove the engine undercover using power tool.
6. Remove the RH inner fender splash shield using power tool.
7. Remove the A/C drive belt.
8. Remove the front exhaust tube.
9. Dismount the A/C compressor with piping attached, and reposition it out of the way securely with wire.

CAUTION: Do not pull on or crimp the A/C lines and hoses.

10. Disconnect the coolant lines from the engine oil cooler and plug them to prevent coolant loss.
11. Remove the oil filter and engine oil cooler from the upper oil pan.
12. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.





13. Remove the front suspension member, as follows:





CAUTION: Before disconnecting, support the front suspension member with a suitable power lift. Use the lift to lower the front the front suspension member to remove it.

a. Disconnect the lower ball joints.
b. Disconnect the power steering line bracket.
c. Disconnect the steering gear mounting bolts.
d. Disconnect the upper sway bar links.
e. Remove the LH and RH drive axles.
f. Disconnect the front engine mounts electrical connectors, if equipped. Remove the front and rear engine mounts through bolts and nuts using power tool.

WARNING: For additional safety, support the engine from above with a suitable hoist.

CAUTION: For vehicles equipped with an automatic transaxle, the front and rear engine mounts are electrically controlled. Disconnect the engine mount electrical connector before removing the through bolt.

g. Remove the front suspension member mounting nuts and lower the member out of the engine compartment.
14. Disconnect the heated oxygen sensors and remove the two catalytic convertors from the exhaust manifolds using power tool.





15. Remove the rear plate cover from the upper oil pan.





16. Remove the bottom oil pan. Loosen the bolts in the numerical sequence as shown with power tool.





a. Insert Tool (Seal cutter KV10111100 [J37228]) between the lower oil pan and the upper oil pan.
^ Be careful not to damage the mating surface.
^ Do not insert a screwdriver, this will damage the mating surfaces.
b. Slide the Tool by tapping its side with a hammer to remove the lower oil pan from the upper oil pan.





17. Remove the four engine-to-transaxle bolts.





18. Remove the upper oil pan.
a. Loosen the bolts in the numerical order as shown, using power tool.





b. Insert an appropriate size tool into the notch (1) of the upper oil pan as shown.
c. Pry off the upper oil pan by moving the tool up and down (2) as shown.





19. Remove the O-ring seals from the bottom of the cylinder block and oil pump housing, use new O-rings for installation.





20. Remove front cover gasket and rear oil seal retainer gasket.





21. If re-installing the original oil pan, remove the old sealant from the mating surfaces using a scraper.
^ Also remove the old sealant from mating surface of the cylinder block.
^ Remove the old sealant from the bolt holes and threads.

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

INSTALLATION

CAUTION: Wait at least 30 minutes before refilling the engine with oil.





1. Apply Genuine Silicone RTV Sealant or equivalent, to the front cover gasket and the rear oil seal retainer gasket as shown.





2. Install the front cover gasket and rear oil seal retainer gasket as shown.








3. Apply a bead of sealant to the cylinder block mating surface of the upper oil pan to a limited portion as shown.
^ Use Genuine Silicone RTV Sealant, or equivalent.
^ Be sure the sealant is applied to a limited portion as shown, and the sealant is 4.0 - 5.0 mm (0.157 - 0.197 inch) or 4.5 - 5.5 mm (0.177 - 0.217 inch) wide.
^ Attaching should be done within 5 minutes after coating.





4. Install new O-rings on the cylinder block and oil pump body.





5. Install the upper oil pan.
^ Tighten bolts in numerical order.
^ Wait at least 30 minutes before refilling the engine with oil.





6. Install the four engine-to-transmission bolts.





7. Apply a continuous bead of sealant to the lower oil pan.
^ Use Genuine Silicone RTV Sealant, or equivalent.
^ Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 inch) wide.
^ Attaching should be done within 5 minutes after coating.





8. Install the lower oil pan. Tighten the bolts in the numerical order as shown.
^ Wait at least 30 minutes before refilling the engine with oil.
9. Install the remaining components in the reverse order of removal.