Oil Pan and Crankcase

Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Lift vehicle by supporting the frame.
3. Remove under cover.
4. Drain engine oil.
5. Remove front wheels.
6. Remove oil level dipstick from level gauge tube.
7. Remove radiator under fan shroud.
8. Remove shift on the fly from axle housing.
9. Remove suspension cross member fixing bolts, 2 pcs each per side and remove suspension cross member.
10. Remove axle housing assembly four fixing bolts from housing isolator side and mounting bolts from wheel side. At this time support the axle with a garage jack and remove axle housing assembly. (for 4x4)
11. Remove the steering unit assembly.
12. Remove starter fixing bolts.
13. Remove oil pan fixing bolts.





14. Remove oil pan, using J-37228 sealer cutter, remove oil pan.
15. Remove crankcase fixing bolts.





16. Remove crankcase, using J-37228 sealer cutter, remove crankcase.

Note: Do not deform or damage the flange of oil pan and crankcase. Replace the oil pan and/or crankcase if deformed or damaged.

Installation
1. Install crankcase.
A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly.





B. Properly apply a 4.5 mm (0.8 inch) wide bead of sealant (TB-1207C or equivalent) to mounting surface of crankcase.
Sealant bead must be continuous.
^ The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.





C. Install crankcase, tighten crankcase fixing bolts to the specified torque.
Torque: 10 Nm (7.4 ft. lbs.)
2. Install oil pan
A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly.





B. Properly apply a 4.5 mm (0.8 inch) wide bead of sealant (TB-1207C or equivalent) to mounting surface of oil pan.
Sealant beat must be continuous.
^ The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.
C. Install oil pan, tighten oil pan fixing bolts to the specified torque.
Torque: 10 Nm (7.4 ft. lbs.)
3. Install starter and tighten fixing bolts.
Torque: 40 Nm (29.5 ft. lbs.)





4. Install axle housing assembly and tighten fixing bolts to the specified torque. (for 4x4)
Axle case bolts
Torque: 82 Nm (61 ft. lbs.)
Mounting bolts
Torque: 152 Nm (112 ft. lbs.)
5. Install the shift on the fly.
6. Install relay lever assembly and tighten fixing bolts.
Torque: 44 Nm (33 ft. lbs.)





7. Install suspension cross member and tighten fixing bolts to the specified torque.
Torque: 78 Nm (58 ft. lbs.)
8. Install radiator under fan shroud.
9. Install under cover.
10. Install engine oil level dipstick.
11. Fill engine oil until full level on engine oil gauge dipstick.