Oil Pan: Service and Repair

Fig. 3 Oil Pan Steel Bolt Loosening Sequence:

1. Remove engine undercover, then drain engine oil.
2. Remove steel oil pan as follows:
a. Remove oil pan attaching bolts. Loosen bolts in sequence, Fig. 3.
b. Insert seal cutter KV10111100 or equivalent between cylinder block and oil pan. Do not use a screwdriver.
c. Slide seal cutter by tapping with hammer.
d. Remove baffle plate and front tube.
e. Place a suitable transmission jack under transaxle, then hoist engine with suitable lifting device.
f. Remove center member.
g. On models with automatic transaxle, remove shift control cable.
h. On all models, remove compressor gussets and rear cover plate.

Fig. 4 Oil Pan Aluminum Bolt Loosening Sequence:

Fig. 5 Transaxle Bolt Removal:

3. Remove aluminum oil pan as follows:
a. Remove attaching bolts. Loosen bolts in sequence, Fig. 4.
b. Remove two engine to transaxle bolts, then refit them into vacant holes as shown in Fig. 5. Tighten bolts to release aluminum oil pan from cylinder block.
c. Insert seal cutter KV10111100 or equivalent between cylinder block and oil pan. Do not use a screwdriver.
d. Slide seal cutter by tapping with hammer and remove oil pan.
d. Remove transaxle bolts as previously installed in oil pan.
4. Reverse procedure to install, noting the following:
a. Apply a continuous bead of suitable sealant .157-.197 inch wide to oil pan mating surface.
b. Tighten bolts in reverse order of removal.
c. Wait at least 30 minutes before refilling engine oil.