Manual Transmission

Oil Pan - Manual Transmission





Special Tool(s)





Material

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the air cleaner outlet tube.





3. Remove the accelerator cable splash shield.





4. Disconnect the accelerator and speed control cables and remove the return spring.





5. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.





6. Disconnect the Positive Crankcase Ventilation (PCV) tube and the vacuum hoses.





7. Disconnect the vacuum hose.





8. Disconnect the Idle Air Control (IAC) motor electrical connector and the bypass hose.
^ Remove the routing clip for the IAC hose.





9. Disconnect the Throttle Position (TP) sensor electrical connector.





10. NOTE: The IAC valve is shown removed for clarity.

Position aside the throttle body adapter.
^ Remove the four adapter bolts.
^ Position aside the throttle body adapter.
^ Remove and discard the throttle body adapter gasket.





11. Hold the accelerator pedal in place and disconnect the accelerator cable from the accelerator pedal and shaft.





12. Disconnect the accelerator cable routing clip from the dash panel stud.





13. Remove the bolts and pull the accelerator cable through the bulkhead.
14. Remove the generator.





15. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

Using the special tools, remove the cooling fan and the fan clutch from the coolant pump pulley.





16. Install the special tool on the engine using the generator mounting holes.





17. Install the special tool.





18. Disconnect the Heated Oxygen Sensor (H02S) electrical connectors.





19. Remove the exhaust Y-pipe flange nuts.





20. Remove the nuts and the exhaust Y-pipe.





21. Remove the engine mount nuts.
22. Remove the starter motor.





23. Remove the stud bolt and the ground strap from the engine.





24. Remove the nut and bracket from the engine front cover stud and position aside the wire harness.





25. Remove the transmission mount nuts.





26. Drain the engine oil and remove the oil filter.





27. Remove the oil cooler threaded insert and position the oil cooler aside.





28. CAUTION: Use care when raising the engine, so that the engine does not touch the body.

Using the special tool, raise the engine.
29. Remove the bolts and remove the RH engine mount from the engine.





30. Remove the bolts and partially lower the oil pan.





31. Remove the oil pump screen and pickup tube and spacer and let them drop into the oil pan.





32. NOTE: To remove the oil pan, position the rear of the pan to the left side of the vehicle and rotate slightly to the right while pulling outward.

Remove the oil pan and the oil pan gasket.
33. Clean the inside of the oil pan thoroughly and inspect the oil pan gasket.

34. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the mating surfaces for the oil pan and the engine with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Installation





1. NOTE: The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.

NOTE: To install the oil pan, position the oil pan to the left rear side of the engine and rotate slightly while sliding the front of the pan toward the right side of the engine.

Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.





2. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.

Install the oil pump screen and pickup tube.
1 Install and tighten the spacer.
2 Position the oil pump screen and pick-up tube on the engine.
3 Install the bolts.





3. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.





4. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.





5. NOTE: Be sure to tighten the bolts in two stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90°.
6. Position the RH engine mount on the engine and install the bolts.
^ Tighten the bolts to 80 Nm (59 ft. lbs.).





7. Using the special tool, lower the engine and remove the special tool.
8. Install the starter motor.





9. Position the oil cooler and install the threaded insert.





10. Install a new oil filter.





11. NOTE: Make sure that both the engine and transmission mounts are correctly seated before installing the mounting nuts.

Install the engine mount nuts.





12. Install the transmission mount nuts.





13. Position the wire harness and install the bracket and nut on the engine front cover stud.





14. Install the ground strap to the engine.





15. Position the exhaust Y-pipe and install the nuts on the exhaust manifold studs.





16. Install the exhaust Y-pipe flange nuts.





17. Connect the heated oxygen sensor electrical connectors.





18. Remove the special tool.





19. Using the special tools, install the cooling fan and the fan clutch to the coolant pump pulley.
20. Install the generator.





21. Install the accelerator cable bracket.
^ Position the accelerator cable through the bulkhead.
^ Install the bolts.





22. Connect the accelerator cable routing clip to the dash panel stud.





23. Connect the accelerator cable to the accelerator pedal and shaft.





24. NOTE: The Idle Air Control Valve (IAC) is shown removed for clarity.

Position back the throttle body adapter.
^ Position a new throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install four bolts and tighten in two stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 90°.





25. Connect the TP sensor electrical connector.





26. Connect the IAC motor bypass hose and connector.
^ Install the routing clip for the IAC hose.





27. Connect the vacuum hose.





28. Connect the PCV tube and the vacuum hoses.





29. Position the accelerator bracket.
^ Position the bracket.
^ Install the bolts.





30. Connect the accelerator and speed control cables and return spring.





31. Install the accelerator cable splash shield.
32. Install the air cleaner outlet tube.

33. CAUTION: The oil pump must be primed prior to starting the engine.

Fill the engine with clean engine oil.