Oil Pan Removal/Installation [In - Vehicle Procedure]

REVISED ENGINE OIL PAN REMOVAL AND INSTALLATION PROCEDURE

The content of this article/image reflects the changes identified in TSB 01-011/12.

DESCRIPTION

If the engine oil pan removal is necessary, use the following procedure to remove and install the engine oil pan. It is no longer necessary to remove the engine assembly.

NOTE: Do not use the current Workshop Manual procedure for oil pan removal/installation.









NOTE: These part numbers are for reference only. Cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

OIL PAN REMOVAL PROCEDURE

Two-Wheel Drive (2WD) and All-Wheel Drive (AWD)

WARNING:

- Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled.

- A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.

- Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.

1. Remove the Air Cleaner Case.

2. Remove the battery tray.

3. Remove the oil level indicator.





4. Remove the starter fixing bolt.





5. Remove the harness bracket.





6. Loosen the 3 upper bellhousing-to-engine bolts 3 mm (0.12 in).





7. Remove the following parts to install the engine support kit 49C0-17-5A0 special service tool (SST).

a. Remove the windshield wiper arm and blade..

b. Remove the cowl grille.

c. Remove the cowl panel.

d. Remove the front cooler pipe fixing bolt (A) and move the front cooler pipe (B) out of the way.





8. Install the engine support kit SST 49C0-17-5A0 and support hanger SST 49L0-17-5A0. The tools are available on Mstore.





9. Lift the vehicle.

10. Remove the drain plug and drain the engine oil.

Install the drain plug and tighten to 27 N-m (20 ft-lbf).

11. Remove and discard the engine oil filter.

12. Remove the exhaust front pipe (A). Discard (C), (D) and (E) exhaust gaskets.

NOTE: The middle pipe (B) does not require removal.





13. Use electrical wire to temporarily support the exhaust middle pipe (B).





14. Remove the No.1 engine mount bracket bolts (A-B).





All-Wheel Drive (AWD) - Steps 15-28 are for AWD only

15. Remove the RH wheel and tire.

16. Remove the RH side cover.

17. Remove the RH front ABS wheel-speed sensor.





18. Knock the crimped portion of the hub nut outward using a small chisel and a hammer.





19. Apply the brake to keep the half shaft from rotating for the front wheel hub nut removal.

20. Loosen the wheel hub nut so that the nut is flush with the end of the drive shaft.

21. Tap the hub nut with a copper or dead-blow hammer to loosen the drive shaft from the front wheel hub. Remove and discard the wheel hub nut.





22. Remove the brake caliper component from the steering knuckle and suspend it out of the way using a cable.





23. Remove the front lower arm ball joint bolt (A) and nut (B). Then separate the lower control arm from the knuckle.





24. Pull the knuckle outward, rotate it toward the rear of the vehicle, and secure it.





25. Remove the 2 joint shaft nuts, then remove the drive shaft and joint shaft as an assembly.





CAUTION: The sharp edges of the drive shaft can slice or puncture the oil seals. Be careful when removing the drive shaft from the transaxle.

26. Remove the RH catalytic converter.

27. Remove the 5 Transfer bracket bolts and the Transfer bracket.





28. Remove the Transfer assembly (A).





Two-Wheel Drive (2WD) and All-Wheel Drive (AWD)

29. Loosen the A/C compressor bolt and slide it out until it is no longer threaded to the oil pan.





30. Remove the ATF cooler bolts and move the cooler out of the way.





31. Loosen the 3 LH bellhousing-to-engine bolts 3 mm (0.12 in) maximum.

CAUTION: Loosening the bolts more than 3mm may dislocate the torque converter oil pump key and cause damage to the transmission.





32. Loosen the RH engine-to-bellhousing bolt 3 mm (0.12 in) maximum.





33. Remove the 2 fasteners and the inspection cover.





34. Remove the 4 oil pan-to-bellhousing bolts.





35. Remove the Warm Up Three Way Catalytic Converter LH bracket (A).





36. Separate the engine and transaxle 3 mm (0.12 in) maximum. Insert a wedge between the transmission and engine block.

CAUTION: Loosening the bolts more than 3mm may dislocate the torque converter oil pump key and cause damage to the transmission.





37. Remove the RH engine splash shield.

38. Remove the 4 lower engine front cover bolts.





39. Remove the 16 oil pan bolts.





40. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.





41. Clean the engine oil pan using a 3M� Roloc� Bristle Disk (2-in white) in a suitable tool turning at the recommended speed of 15,000 rpm.

NOTE: Only use a 3M� Roloc� Bristle Disk (2-in white) to clean the oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.

- Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.

42. Clean the sealing surfaces of the cylinder block and engine front cover.

- Remove any large deposits of silicone or gasket material.

- Use a suitable plastic scraper and brake clean to remove remaining silicone deposits and motor oil residual.

NOTE: Do not use wire brushes, power abrasive discs or 3M� Roloc� Bristle Disk (2-in white) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.

OIL PAN INSTALLATION PROCEDURE

Two-Wheel Drive (2WD) and All-Wheel Drive (AWD)

1. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the 2 engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.





2. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the engine front cover-to-oil pan mating surface.





3. Apply a 3 mm (0.11 in) bead of Mazda Gray RTV Silicone Gasket Maker to the sealing surface of the oil pan-to-engine block mating surface.

NOTE:

- Failure to use Mazda Gray RTV Silicone Gasket Maker may cause the engine oil to foam excessively and result in serious engine damage.

- The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.





4. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.





5. With the help from an assistant, install the oil pan and bolts 10, 11, 13 and 14 finger tight.

NOTE:

- The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

- Keep the oil pan as close as possible to the transmission while installing, then slide forward towards the engine front cover to prevent wiping off of the sealant.





6. Install the A/C compressor bolt.

- Hand tighten the bolt.





7. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 N-m (27 in-lbf).





8. Install the 4 lower engine front cover bolts.

- Do not torque at this time.





9. Install the remaining oil pan bolts and tighten in the four steps shown.

- Step 1 - Tighten all bolts in sequence to 3 N-m (27 in-lbf).

- Step 2 - Loosen all bolts 180 degrees.

- Step 3 - Tighten bolts 1 through 14 in sequence to 20-28 N-m (15-20 ft-lbf).

- Step 4 - Tighten bolts 15 and 16 to 8.5-11.5 N-m (76-101 in-lbf).





10. Tighten the 4 lower engine front cover bolts in two steps.

- Step 1 - Tighten bolts to 10 N-m (89 in-lbf).

- Step 2 - Tighten bolts to 20-28 N-m (15-20 ft-lbf).





11. Install the RH engine splash shield.

12. Tighten the A/C compressor bolt to 24-36 N-m (18-26 ft-lbf).





13. Remove the wedge between the transmission and engine block and draw the bellhousing up to the engine by tightening the LH bellhousing-to-engine bolt.

- Do not tighten at this time.





14. Draw the bellhousing up to the engine by tightening the RH engine-to-bellhousing bolt.

- Do not tighten at this time.





15. Install the Warm Up Three Way Catalytic Converter LH bracket (A).





16. Install the 4 oil pan-to-bellhousing bolts.

- Do not tighten at this time.





17. Tighten the 4 oil pan-to-bellhousing bolts to 37-52 N-m (28-38 ft-lbf).





18. Tighten the RH engine-to-bellhousing bolt to 37-52 N-m (28-38 ft-lbf).





19. Tighten the 3 LH bellhousing-to-engine bolts to 37-52 N-m (28-38 ft-lbf).





20. Install the ATF cooler. Tighten bolts to 19-25 N-m (2.0-2.5 kgf-m, 14-18 ft-lbf).





21. Install the inspection cover and the 2 fasteners.





All-Wheel Drive (AWD) - Steps 22-27 are for AWD only

22. Install the Transfer assembly (A).





23. Install the Transfer assembly support bracket.

- Tighten the 5 Transfer bracket bolts to 70 N-m (52 ft-lb).





24. Install the RH catalytic converter with new upper exhaust gasket (P/N CY01-40-450).

25. Install the RH drive shaft and RH wheel in reverse order.

- Tighten the 2 drive shaft support nuts to 40 N-m (30 ft-lb).

- Install new RH hub nut, tighten to 235.2-274.4 N-m (173.5-202.3 ft-lb) and stake it.





CAUTION: The sharp edges of the drive shaft can slice or puncture the oil seals. Be careful when installing the drive shaft into the transaxle.

26. If necessary, top off Tranfer oil with SAE 75W-140 Premium High Performance Rear Axle Lubricant (0000- 77-W140-QT).

Two-Wheel Drive (2WD) and All-Wheel Drive (AWD)

27. Tighten the 3 upper bellhousing-to-engine bolts to 37-52 N-m (28-38 ft-lbf).





28. Install the harness bracket and tighten the bolts to 8-10 N-m (71-88 in-lbf).





29. Install the starter fixing bolt. Tighten bolt to 27 N-m (2.8 kgf-m, 20 ft-lbf).





30. Install a new engine oil filter.

- Install the oil filter until the O-ring contacts the sealing surface.

- Tighten the oil filter 3/4 turns by hand.

NOTE: Do not lubricate the engine oil filter gasket.

31. Install the No.1 engine mount bracket bolts (A) and (B) in order of (A) => (B).
Tighten the bolts to 93.1-116.6 N-m (9.5-11.8 kgf-m, 68.7-85.9 ft-lbf)





32. Install the exhaust front pipe (A) with new (C), (D) and (E) exhaust gaskets.





33. Lower the vehicle.

34. Remove the engine support kit SST 49C0-17-5A0 and support hanger SST 49L0-17-5A0.





35. Install the following parts after removing the SST.

a. Install the front cooler pipe fixing bolt (A). Tighten bolt to 8-12 N-m (82-122 kgf-cm, 71-106 in-lbf)





b. Install the cowl panel.

c. Install the cowl grille.

d. Install the windshield wiper arm and blade.

36. Install the oil level indicator.





37. Install the battery tray.

38. Install the Air Cleaner Case.

39. Fill the engine with clean engine oil.

NOTE: 2007-2009 CX-9 vehicles, refer to TSB 01-044/08 for engine oil level service caution.

SPECIAL SERVICE TOOL(S) INFORMATION





PART(S) INFORMATION