Oil Pan: Service and Repair

Oil Pan Replacement

Tools Required

J 41820 Ball Joint Separator

Removal Procedure




1. Install the engine support fixture. Refer to Engine Support Fixture (Engine Support Fixture).
2. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (Service and Repair).
3. Remove the right front splash shield. Refer to Engine Splash Shield Replacement (Service and Repair).
4. Remove the oil pan drain plug.
5. Drain the crankcase.
6. Reinstall the oil pan drain plug until snug.




7. Remove the engine harness clips from the right lower control arm.




8. Remove and discard the lower ball joint castle nut cotter pin (1).
9. Remove the lower ball joint castle nut (1).




10. Install the overJ 41820 the ball stud and lower control arm as shown.
11. Rotate the ball stud nut counterclockwise in order to separate the ball stud from the steering knuckle




12. Remove the air conditioning (A/C) compressor front bolt and nut.




13. Remove the A/C compressor rear bolt and position the compressor aside.




14. Remove the transaxle brace to engine block/oil pan bolts.
15. Remove the transaxle brace to transaxle bolts.
16. Remove the transaxle brace.




17. Remove the transaxle brace to oil pan bolts.
18. Remove the transaxle brace to transaxle bolt.
19. Remove the transaxle brace.
20. Remove the starter. Refer to Starter Motor Replacement (Service and Repair).




21. Disconnect the engine harness electrical connector from the oil level sensor.




22. Remove the engine harness clip from the oil pan.
23. Remove the engine mount. Refer to Engine Mount Replacement (Service and Repair).




24. Place adjustable jack stands under the frame.
25. Loosen the left side frame bolts (2) and remove the right side frame bolts (1).
26. Using the jack stands, lower the right side of the frame enough to remove the oil pan.




27. Remove the oil pan side bolts (1).
28. Remove the oil pan bolts (2).
29. Remove the oil pan.
30. Remove the oil pan gasket.
31. Clean the following items:

* The oil pan flanges
* The oil pan rail
* The front cover
* The rear main bearing cap
* The threaded holes

Installation Procedure




1. Apply sealer to both sides of the crankshaft rear main bearing cap (1). Refer to Sealers, Adhesives, and Lubricants (Specifications). Press sealer into the gaps using a putty knife.




2. Install the oil pan gasket.
3. Install the oil pan.

Notice: Refer to Fastener Notice (Fastener Notice).

4. Install the oil pan bolts (2).

Tighten the bolts to 25 N.m (18 lb ft).

5. Install the oil pan side bolts (1).

Tighten the bolts to 50 N.m (37 lb ft).




6. Using the jack stands, raise the right side of the frame.
7. Install and tighten the right side frame bolts (1) and tighten the left side frame bolts (2).

* Tighten the front frame bolts to 130N.m (96 lb ft).
* Tighten the rear frame bolts to 240 N.m (177 lb ft).

8. Remove the adjustable jack stands from under the frame.




9. Install the engine mount. Refer to Engine Mount Replacement (Service and Repair).
10. Install the engine harness clip to the oil pan.




11. Connect the engine harness electrical connector to the oil level sensor.




12. Install the starter. Refer to Starter Motor Replacement (Service and Repair).
13. Position the transaxle brace to the transaxle and oil pan.
14. Install the transaxle brace to transaxle bolt.
15. Install the transaxle brace to oil pan bolts.

Tighten the bolts to 43 N.m (32 lb ft).




16. Position the transaxle brace to the transaxle and the engine block/oil pan.
17. Install the transaxle brace to transaxle bolts.
18. Install the transaxle brace to engine block/oil pan bolts.

Tighten the bolts to 43 N.m (32 lb ft).




19. Position the A/C compressor over the front stud and install the A/C compressor front bolt and nut.

Tighten the bolt/nut to 50 N.m (37 lb ft).




20. Install the A/C compressor rear bolt.

Tighten the bolt to 50 N.m (37 lb ft).




21. Install the lower ball joint to the steering knuckle.
22. Install the lower ball joint castle nut (1).

Tighten the nut to 55 N.m (40 lb ft).





Important: Do not loosen the castle nut in order to align the slots to the ball joint stud pin hole.


23. If necessary, tighten the castle nut in order to align one of the slots (1) to the ball joint stud pin hole (2) as shown.




24. Install a NEW cotter pin to the castle nut and ball joint stud.
25. Bend the NEW cotter pin ends as shown in either example.




26. Install the engine harness clips to the right lower control arm.




27. Install the right front splash shield. Refer to Engine Splash Shield Replacement (Service and Repair).
28. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (Service and Repair).
29. Remove the engine support fixture. Refer to Engine Support Fixture (Engine Support Fixture).
30. Fill the crankcase with NEW oil.