Disassembly and Assembly

OIL PAN (UPPER) AND OIL STRAINER


2WD : Disassembly and Assembly


REMOVAL

CAUTION:
Never drain engine oil when the engine is hot to avoid the danger of being scalded.
1. Remove oil pan (lower). Exploded View.
2. Remove oil strainer.





3. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove.

White Arrow : Engine front

- Insert the seal cutter [SST: KV10111100] between oil pan
(upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper).

CAUTION:
- Be careful not to damage the mating surfaces.
- Never insert a screwdriver, because this damages the mating surfaces.





4. Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3).

White Arrow : Engine front


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





a. Install O-ring (2) on the bottom of lower cylinder block (1) and oil pump (3).

White Arrow : Engine front






b. Install oil pan gaskets (both front and rear).

C : Liquid gasket application position
a : 15mm (0.59 in)
b : 5mm (0.20 in)

- Apply liquid gasket (an equivalent of Three Bond 1218B) to the area of oil pan gasket shown in the figure in a seamless single layer. Liquid Gasket





- To install oil pan gasket (1), align the protrusion (B) with the notches (A) of the front timing chain case and the rear oil seal retainer..

White Arrow : Engine front

- Install the oil pan gasket with smaller arc to the front timing chain case side.





c. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure.

a : diameter 4.5-5.5mm (0.177 - 0.217 in)
b : 35mm(1.38 in)
c : diameter 4.0-5.0mm (0.157 - 0.197 in)
White Arrow : Engine front

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

CAUTION:
- For bolt holes with marks (5 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 O-rings.





- Tighten mounting bolts in numerical order as shown in the figure.

White Arrow : Engine front

- There are three types of mounting bolts. Refer to the following for locating bolts.

M8 x 100 mm (3.94 in) : 5,7,11
M8 x 25 mm (0.98 in) : Except the above

2. Install oil strainer to oil pump.
3. Install oil pan (lower). Exploded View.
4. Install oil pan drain plug.
- Refer to the figure of components of former page for installation direction of drain plug washer. Exploded View.
5. Install in the reverse order of removal after this step.

NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.