Oil Pan: Service and Repair
REPLACE THE OIL SUMP
Special tools: 951 1205, 999 5460, 999 5716, 999 5972
Preparation
Remove the ignition key.
Installing the lifting beam and lifting hook
Position the lifting yoke as illustrated.
Tension slightly.
Removing components
Remove
- the mass air flow (MAF) sensor from the air cleaner (ACL) housing
- the upper section of the air cleaner (ACL) housing
- the preheating hose.
Removing the front suspension
Slacken off the upper nuts for the engine pads a few turns.
Note! Do not remove the nuts yet.
Remove the four mounting screws from the front suspension member.
Raise the car.
Remove the splashguard under the engine.
Drain the engine oil and remove the oil filter.
Remove
- the mounting brackets for the anti-roll bar. Allow the anti-roll bar to hang
- the remote oil filter
- the 4 mounting screws for the wiring harness from the engine
- the pre-heating pipe
- the upper screw for the steering joint.
Note! Remember the safety catch for the steering shaft joint.
Release the oil cooler from the sump. Hang up at the rear.
Disconnect the power steering pipe from the clip mounting.
Lowering the front suspension
Position the mobile jack under the front suspension member. Use lifting plate 999 5972.
Secure using an M8 screw in the member.
Remove the screws for the rear mounting for the rear control arms.
Lower the front suspension 12 cm using the mobile jack.
Caution! Do not stretch the power steering hoses.
Removing the oil sump
Slacken off all the screws holding the oil sump.
Remove all screw except for four. It is recommended that the four screws in the corners of the sump are left in place.
Carefully tap the sump with a rubber mallet until the joint and its liquid gasket releases.
Remove the four remaining screws.
Remove the sump.
Cleaning
Clean the gasket surface on the oil sump and cylinder block. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.
Warning! Use a fume hood or extractor when using gasket solvent.
Installing the oil sump
Apply liquid gasket 1161 059-9 to the oil pan. Use roller 951 1205.
Install
- new 0-rings
- the oil sump. Secure the oil sump loosely using a few screws
- the remaining screws loosely.
Press the oil sump against the transmission.
Tighten the screws (1), (2), (3) and (4). Tighten to 3 Nm.
Tighten the screws (5). First tighten to 25 Nm.
Then tighten to 48 Nm.
Tighten all screws in the oil sump joint. Tighten to 17 Nm.
Start at the transmission and continue forwards in pairs.
Installing the pre-heating pipe
Install the pre-heating pipe under the engine.
Tighten to 24 Nm.
Installing the front suspension
Raise the front suspension to contact. Use the mobile jack.
Note! At the same time align the steering shaft joint.
Install
- the screws for the front suspension and the engine mountings by hand from underneath the screws for the rear mounting point for the trailing arms. Tighten to contact the anti-roll bar. Tighten to 50 Nm.
Tightening the front suspension member
Remove the mobile jack.
Lower the car.
Tighten the front suspension screws. Tighten to 95 Nm.
Tighten the engine mounting nuts. Tighten to 50 Nm.
Removing the lifting beam
Remove the lifting beam and accessories.
Installing components
Install
- the preheating hose
- the upper section of the air cleaner (ACL) housing
- the intake hose between the mass air flow (MAF) sensor and the throttle body (TB).
Tightening
Tighten the screws for the rear mounting of the trailing arms. For cars to model year -94 inclusive, tighten to 120 Nm. For cars from model year -95 inclusive, tighten to 100 Nm.
Tighten the screws for the steering shaft joint. Tighten to 24 Nm.
Install
- the safety catch for the steering shaft joint
- the power steering pipe in the clip
- the remote oil filter assembly using a new 0- ring. Tighten the pipe screw. Tighten to 65 Nm a new oil filter.
Check
Fill with engine oil. Run the engine to operating temperature.
Check for oil leaks from the oil sump or oil cooler.
Install the splashguard under the engine.
Check the oil level. Top up if required.