Oil Pan: Service and Repair
OIL PAN AND OIL STRAINERComponents (2WD Model):
Image Symbols:
Removal and Installation
REMOVAL
WARNING: To avoid the danger of being scalded, do not drain the engine oil when the engine is hot.
NOTE: To remove oil pan (lower) only, take step 4 and step 5, then step 21. Step 1 to 3 and 6 to 20 are unnecessary.
1. Remove hood assembly.
2. Remove engine cover with power tool.
3. Remove air duct.
4. Remove undercover with power tool.
5. Drain engine oil.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.
6. Drain engine coolant.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
7. Disconnect heater hose from heater pipe.
8. Install engine slinger to sling engine assembly for positioning.
9. Remove front suspension member.
10. Remove drive belts.
11. Remove alternator.
12. Remove idler pulley.
13. Remove starter motor.
14. Disconnect oil cooler water hoses, and remove oil cooler water pipe mounting bolt.
15. Remove oil filter, as necessary.
16. Remove oil cooler, as necessary.
17. Remove oil pressure switch, as necessary.
18. Remove oil temperature sensor, as necessary.(M/T models)
19. Disconnect A/T fluid cooler hoses, and remove A/T fluid cooler tube (A/T models).
20. Remove crankshaft position sensor (POS).
CAUTION:
^ Handle carefully to avoid dropping and shocks.
^ Do not disassemble.
^ Do not allow metal powder to adhere to magnetic part at sensor tip.
^ Do not place sensors in a location where they are exposed to magnetism.
21. Remove oil pan (lower) as follows:
a. Loosen mounting bolts with power tool in reverse order as shown in the figure to remove.
b. Insert seal cutter [SST] between oil pan (upper) and oil pan (lower).
CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert screwdriver, this will damage the mating surface.
c. Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (lower).
22. Remove baffle plate.
23. Remove oil strainer.
24. Remove transmission joint bolts which pierce oil pan (upper).
25. Remove rear plate cover.
26. Loosen mounting bolts with power tool in reverse order as shown in the figure to remove oil pan (upper).
^ Insert seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (upper).
CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert screwdriver, this will damage the mating surfaces.
27. Remove O-rings from bottom of cylinder block and oil pump.
28. Remove oil pan gaskets.
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
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 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 oil pan gaskets.
^ Apply liquid gasket to oil pan gaskets as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent.
^ To install, align protrusion of oil pan gasket with notches of front timing chain case and rear oil seal retainer.
^ Install oil pan gasket with smaller arc to front timing chain case side.
c. Install new O-rings on the bottom of cylinder block and oil pump.
d. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
CAUTION:
^ For bolt holes with (arrow up) marks (five locations), apply liquid gasket outside the holes.
^ Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 inch) in diameter to area "A".
^ Attaching should be done within 5 minutes after coating.
e. Install the oil pan (upper).
^ Tighten mounting bolts in numerical order as shown in the figure.
^ There are two types of mounting bolts. Refer to the following for locating bolts.
M8 � 100 mm (3.97 inch): 5, 7, 8, 11
M8 � 25 mm (0.98 inch): Except the above
f. Tighten transmission joint bolts.
2. Install oil strainer to oil pump.
3. Install baffle plate.
^ Apply locking sealant to the thread of mounting bolts.
Use Genuine High Strength Thread Locking Sealant or equivalent.
4. 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 with tube presser [SST: WS39930000 ( - )] to the oil pan (lower) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
CAUTION: Attaching should be done within 5 minutes after coating.
c. Install oil pan (lower).
^ Tighten mounting bolts in numerical order as shown in the figure.
5. Install oil pan drain plug.
^ Refer to the figure of components of former page for the installation direction of drain plug washer. Refer to EM-31, "Components (2WD Model)".
6. Install in the reverse order of removal after this step.
NOTE: At least 30 minutes after oil pan is installed, pour engine oil.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and adjust engine oil.
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.