Removal and Installation
OIL PAN AND OIL STRAINER
AWD : Removal and Installation
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
CAUTION:
To remove oil pan (upper), remove engine assembly first.
NOTE:
When removing oil pan (lower) only, remove engine assembly is not necessary. Perform step 1, 2 and 10.
1. Remove front and rear undercover with power tool.
2. Drain engine oil. Refer to Service and Repair.
CAUTION:
- Perform this step when engine is cold.
- Never spill engine oil on drive belt.
3. Remove engine assembly from the vehicle, and separate front suspension member and transmission from engine. Refer to Component.
4. Lift the engine with hoist, and mount it onto widely use engine stand. Refer to Component.
5. Remove alternator. Refer to Service and Repair.
6. Remove starter motor. Refer to Removal and Replacement.
7. Remove idler pulley and bracket assembly. Refer to Exploded View.
8. Remove oil filter, if necessary. Refer to Removal and Installation.
9. Remove oil temperature sensor, if necessary.
10. 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: KV10111100 (J37228)] (A) between oil pan (upper) and oil pan (lower).
CAUTION:
- Be careful not to damage the mating surfaces.
- Never insert screwdriver, this will damage the mating surface.
11. Remove oil strainer.
12. Remove rear cover plate.
13. 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 mating surfaces.
- Never insert screwdriver, this will damage the mating surface.
14. Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3).
15. Remove axle pipe, if necessary.
- Remove axle pipe from oil pan (upper) using a suitable drift (A)
[outer diameter: 37 mm (1.46 in)].
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install axle pipe (3) to oil pan (upper), if removed.
- Lubricate O-ring groove of axle pipe, O-rings (1), (2), and Oring joint of oil pan with new engine oil.
- Install axle pipe (1) to oil pan (upper) from axle pipe flange side (left side) using a suitable drift (A) [outer diameter: 43 to
57 mm (1.69 to 2.24 in)].
CAUTION:
Insert it with care to prevent O-ring from sliding.
2. Install oil pan (upper) as follows:
a. Use scraper (A) 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:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3).
c. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the lower cylinder block mating surface 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.
CAUTION:
- For bolt holes (B) (7 locations), apply liquid gasket outside the holes.
- Attaching should be done within 5 minutes after coating.
d. Install oil pan (upper).
CAUTION:
Install avoiding misalignment of both oil pan gasket and O-rings.
- Tighten mounting bolts in numerical order as shown in the figure.
- There are three types of mounting bolts. Refer to the following for locating bolts.
M8 � 25 mm (0.98 in) : 3, 6, 8, 9, 11, 12, 14, 15, 16
M8 � 50 mm (1.97 in) : 2
M8 � 90 mm (3.54 in) : 1, 4, 5, 7, 10, 13
e. Tighten transmission joint bolts. Refer to Service and Repair.
3. Install oil strainer to oil pump.
- Apply locking sealant to the thread of mounting bolts.
Use genuine high strength thread locking sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
4. Install oil pan (lower) as follows:
a. Use scraper (A) 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:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) (A) to the oil pan (lower) as shown in the figure.
b : diameter 4.0 - 5.0 mm (0.157 - 0.197 in)
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 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 installation direction of drain plug washer. Refer to Service and Repair.
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. Refer to Testing and Inspection.
2. Start engine, and check there is no leakage of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to Testing and Inspection.
4. Check engine oil level again. Refer to Testing and Inspection.