Oil Pan: Service and Repair
Oil PanService Repair No - 12.60.44
Removal
1. Disconnect the battery ground cable.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Raise and support the vehicle.
3. Remove the engine.
NOTE: Restrain the pulley to aid the removal of the bolts.
4. Remove the cooling fan pulley.
^ Remove the 3 bolts.
5. Remove the cooling fan drive hub bearing.
^ Remove the 5 bolts.
6. Release the accessory drive belt.
^ Rotate the accessory drive belt tensioner counter-clockwise.
NOTE: Note the fitted position.
7. Remove the accessory drive belt.
8. Remove the accessory drive belt tensioner.
^ Remove the bolt.
9. Remove the A/C compressor.
^ Remove the 3 bolts.
^ Disconnect the electrical connector.
10. Remove the A/C compressor mounting bracket.
^ Remove the 2 bolts.
11. Remove the cooling fan drive belt tensioner.
^ Remove the bolt.
12. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
13. Disconnect the cylinder block coolant hose.
^ Release the clip.
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
14. Release the coolant manifold.
^ Remove the 4 screws.
^ Position the wiring harness bracket aside.
^ Remove and discard the 2 O-ring seals.
15. Disconnect the coolant manifold rear hose.
^ Rotate the coolant manifold.
^ Release the clip.
16. Remove the coolant manifold.
NOTE: Restrain the pulley to aid the removal of the bolts.
17. Remove the coolant pump pulley.
^ Remove the 3 bolts.
18. Remove the accessory drive belt idler pulley.
^ Remove the bolt.
^ Repeat the above procedure for the remaining idler pulley.
19. Remove the exhaust manifold heat shield.
^ Remove the 2 screws.
20. Disconnect the battery positive cable.
^ Release the cover.
^ Remove the nut.
21. Remove the generator.
^ Remove the 3 bolts.
^ Disconnect the electrical connector.
22. Remove the generator mounting bracket.
^ Remove the 4 bolts.
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
23. Using the special tools, lock the crankshaft pulley.
NOTE: The crankshaft pulley bolt will be very tight.
24. Remove and discard the crankshaft pulley bolt.
^ Remove the special tools.
NOTE: The crankshaft pulley will be very tight.
25. Using the special tools, remove the crankshaft pulley.
^ Collect the locking ring.
^ Remove the special tools.
26. Using the special tool, remove and discard the crankshaft front seal.
27. Remove the RH ignition coil-on-plug cover.
^ Release from the 2 clips.
28. Disconnect the ignition coil-on-plug electrical connector.
29. Remove the ignition coil-on-plug.
^ Remove the bolt.
^ Remove and discard the seal.
30. Remove the remaining ignition coil-on-plugs.
31. Disconnect the positive crankcase ventilation (PCV) line.
32. Disconnect the variable camshaft timing (VCT) oil solenoid electrical connector.
33. Release the engine wiring harness.
34. NOTE: Note the fitted position of the bolts prior to removal.
Remove the RH valve cover.
^ Remove the 14 bolts.
35. Remove and discard the valve cover bolt O-ring seals.
36. Remove and discard the valve cover gasket.
37. Remove the valve cover plug aperture seals.
NOTE: RH illustration shown, LH is similar
38. Remove the LH ignition coil-on-plug cover.
^ Release from the 2 clips.
NOTE: RH illustration shown, LH is similar
39. Disconnect the ignition coil-on-plug electrical connector.
NOTE: RH illustration shown, LH is similar
40. Remove the ignition coil-on-plug.
^ Remove the bolt.
^ Remove and discard the seal.
41. Remove the remaining ignition coil-on-plugs.
42. Remove the oil level indicator and tube.
^ Remove the nut.
^ Remove and discard the seal.
43. Disconnect the valve cover breather hose.
44. Disconnect the variable camshaft timing (VCT) oil solenoid electrical connector.
45. Release the engine wiring harness.
^ Release from the 4 clips.
NOTE: Rotate the oil filler pipe counter-clockwise to remove.
46. Remove the oil filler pipe.
^ Release the clip.
NOTE: Note the fitted position of the bolts prior to removal.
47. Remove the LH valve cover.
^ Remove the 14 bolts.
48. Remove and discard the valve cover bolt O-ring seals.
49. Remove and discard the valve cover gasket.
50. Remove the valve cover plug aperture seals.
51. Release the engine wiring harness.
^ Release the 2 clips.
^ Remove the bolt.
52. Remove the engine front cover extension housing.
^ Remove the 4 bolts.
53. Remove the engine front cover.
^ Remove the 24 bolts.
^ Remove and discard the gasket.
^ Remove and discard the 3 O-ring seals.
54. Remove the power steering pump and mounting bracket.
^ Remove the 3 bolts.
55. LH side: Release the wiring harness.
^ Release the 3 clips.
56. RH side: Release the wiring harness.
^ Release the 3 clips.
57. Remove the halfshaft support bearing housing.
^ Remove the 4 bolts.
^ Remove and discard the O-ring seal.
CAUTION: Note the position of the bolts, prior to removal.
58. Remove the oil pan.
^ Remove the 19 bolts.
^ Carefully remove the sealant.
Installation
1. Install the oil pan.
^ Clean the component mating faces.
^ Apply a bead of sealant, 3 mm diameter, to the area indicated.
^ Install the bolts, but do not tighten fully at this stage.
2. Tighten the oil pan bolts in the sequence shown to 20 Nm (15 ft. lbs.).
3. Install the halfshaft support bearing housing.
^ Install a new O-ring seal.
^ Lubricate the O-ring seal with petroleum jelly.
^ Tighten the bolts evenly to 25 Nm (18 ft. lbs.).
4. RH side: Attach the wiring harness.
^ Secure the clips.
5. LH side: Attach the wiring harness.
^ Secure the clips.
6. Install the power steering pump and bracket.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
7. Install the engine front cover.
^ Clean the component mating faces.
^ Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places indicated.
^ Install a new gasket.
^ Install new O-ring seals.
8. Install the engine front cover extension housing.
^ Tighten the M6 bolt to 10 Nm (7 ft. lbs.).
^ Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
9. Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 ft. lbs.).
10. Attach the engine wiring harness.
^ Secure the clips.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).
11 Install new valve cover plug aperture gaskets.
12. Install a new valve cover gasket.
13. Install new valve cover bolt O-ring seals.
NOTE: Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
14. Install the LH valve cover.
^ Clean the component mating faces.
15. Install the valve cover bolts.
^ Install the valve cover bolts to their position previously noted.
^ Tighten the bolts to 12 Nm (9 ft. lbs.).
^ Complete the tightening sequence as illustrated.
16. Install the oil filler pipe.
^ Secure with the clip.
17. Attach the engine wiring harness.
18. Install the oil level indicator and tube.
^ Install a new O-ring seal.
^ Lubricate the O-ring seal with clean engine oil.
^ Tighten the nut to 6 Nm (4 ft. lbs.).
19. Connect the valve cover breather hose.
20. Connect the VCT oil solenoid electrical connector.
21. Install the ignition coil-on-plug.
22. Install the remaining coil-on-plugs.
23. Install new valve cover plug aperture gaskets.
24. Install a new valve cover gasket.
25. Install new valve cover bolt O-ring seals.
26. NOTE: Apply two beads of silicone gasket sealant as shown on the illustration. The application of the sealant must be 3mm diameter 12mm long. Install the valve cover immediately after applying the sealant. The cover should be fitted directly to the head without smearing the sealant or the seals.
Install the RH valve cover.
^ Clean the component mating faces.
27. Install the valve cover bolts.
^ Install the valve cover bolts to their position previously noted.
^ Tighten the bolts to 12 Nm (9 ft. lbs.).
^ Complete the tightening sequence as illustrated.
28. Attach the engine wiring harness.
29. Connect the VCT oil solenoid electrical connector.
30. Connect the PCV line.
31. Install the ignition coil-on-plug.
^ Install a new seal.
^ Tighten the bolt to 6 Nm (4 ft. lbs.).
^ Connect the electrical connector.
32. Install the remaining coil-on-plugs.
33. Install the ignition coil-on-plug cover.
34. Clean all the crankshaft pulley mating faces.
35. Using the special tool, install the crankshaft front seal.
^ Lubricate the seal with clean engine oil.
^ Use the discarded crankshaft bolt with the special tool.
^ Remove the special tools.
36. Install the crankshaft pulley.
^ Lubricate the seal with clean engine oil.
37. Install the crankshaft pulley locking ring.
CAUTION: The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt.
38. Install, but do not tighten, the new crankshaft pulley bolt.
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
39. Using the special tools, lock the crankshaft pulley.
^ Tighten the crankshaft pulley bolt to 380 Nm (280 ft. lbs.).
^ Remove the special tools.
40. Install the generator mounting bracket.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
41. Install the generator.
^ Tighten the 3 bolts to 48 Nm (35 ft. lbs.).
^ Connect the electrical connector.
42. Connect the battery positive cable.
^ Tighten the nut to 10 Nm (7 ft. lbs.).
^ Secure the cover.
43. Install the exhaust manifold heat shield.
^ Tighten the screws.
44. Install the coolant pump pulley.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
45. Install the coolant manifold.
^ Clean the components.
^ Install new O-ring seals.
^ Connect the rear hose and secure with the clip.
^ Connect the cylinder block hose and secure with the clip.
^ Attach the wiring harness bracket.
^ Tighten the screws to 10 Nm (7 ft. lbs.).
46. Connect the remaining coolant hoses.
^ Secure with the clips.
47. Connect the ECT sensor electrical connector.
48. Install the cooling fan drive belt tensioner.
^ Tighten the bolt to 40 Nm (30 ft. lbs.).
49. Install the A/C compressor mounting bracket.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
50. Install the A/C compressor.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
^ Connect the electrical connector.
51. Install the accessory drive belt tensioner.
^ Tighten the bolt to 40 Nm (30 ft. lbs.).
52. Install the accessory drive belt.
53. Install the cooling fan belt tensioner.
^ Tighten the bolt to 40 Nm (30 ft. lbs.).
54. Install the cooling fan drive hub bearing.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
55. Install the cooling fan pulley.
^ Tighten the bolts evenly to 25 Nm (18 ft. lbs.).
56. Install the engine.
57. Connect the battery ground cable.