Disassembly and Assembly

OIL PAN (UPPER)


Disassembly and Assembly


DISASSEMBLY

WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1. Remove oil filter. Refer to Service and Repair.
2. Remove oil cooler. Refer to Exploded View.
3. Remove A/C compressor and A/C compressor bracket. Refer to Exploded View and Exploded View.
4. Remove oil level gauge and oil level gauge guide.
5. Remove oil pressure switch and oil temperature sensor if necessary.
6. Remove rear plate cover.
7. Remove oil pan (lower). Refer to Exploded View.
8. Remove oil strainer. Refer to Exploded View.
9. Remove oil pan (upper) as per the following:





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

NOTE:
Disregard No. 12, 17 when loosening.





b. Insert a suitable tool into the notch at oil pan (upper) (1) as shown.
- Pry off case by moving a suitable tool.

CAUTION:
Be careful not to damage the mating surfaces.
10. Remove O-ring from bottom of cylinder block and oil pump.
11. Remove baffle plate, if necessary.
12. Remove axle pipe from oil pan (upper), if necessary.
- Pull axle pipe from oil pan (upper) using a suitable drift.

ASSEMBLY
1. Install axle pipe (1) to oil pan (upper), if removed.





- Lubricate O-ring groove of axle pipe, O-ring, and O-ring joint of oil pan with new engine oil.
- Install axle pipe to oil pan (upper) from drive shaft (LH) side.

CAUTION:





Insert it with care to prevent O-ring from sliding.
2. Install oil pan (upper) as per the following:





a. Use a scraper (A) to remove old liquid gasket from mating surfaces.
- Also remove the old liquid gasket from mating surface of cylinder block.
- Remove old liquid gasket from the bolt holes and threads.

CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Install new O-rings on the bottom of cylinder block and oil pump.





c. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the cylinder block mating surfaces of oil pan (upper) to a limited portion as shown in the figure.
Use Genuine RTV Silicone Sealant or an equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:





Attaching must be done within 5 minutes after coating.





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

CAUTION:
Install avoiding misalignment of O-rings.

NOTE:
Tighten mounting bolts No. 1 and 2 in two steps. The numerical order No. 12 and 17 shown second steps.
- There are three types of mounting bolts. Refer to the following for locating bolts.

M6 � 30 mm. (1.18 in) : 18, 19
M8 � 100 mm (3.94 in) : 3, 4, 5, 7, 10, 11, 14, 15
M8 � 45 mm (1.77 in) : Except the above

e. Tighten transmission joint bolts.
f. Install rear plate cover.
3. Install oil strainer.
4. Install oil pan (lower). Refer to Removal and Installation.
5. Install in the reverse order of removal.

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