OIL PAN REMOVAL/INSTALLATION [MZR 2.0 DISI]

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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.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [MZR 2.0 DISI].)

1.  Disconnect the negative battery cable.

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

3.  Disconnect the wiring harness.

4.  Remove the high pressure fuel pump and high pressure fuel pump cover. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI].)

5.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 2.0 DISI].)

6.  Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZR 2.0 DISI].)

7.  Disconnect the ventilation hose from the cylinder head cover.

8.  Remove the front wheel and tire. (RH) (See GENERAL PROCEDURES (SUSPENSION).)

9.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

10.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZR 2.0 DISI].)

11.  Set the front mudguard (RH) out of the way. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

12.  Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

13.  Loosen the water pump pulley bolts and remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI].)

14.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)

15.  Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (ATX) (See DRIVE SHAFT REMOVAL/INSTALLATION.)

16.  Remove the engine front cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI].)

17.  Remove in the order indicated in the table.

18.  Install in the reverse order of removal.

19.  Refill with the specified type and amount of the engine oil. (See ENGINE OIL REPLACEMENT [MZR 2.0 DISI].)

20.  Start the engine and confirm that there is no oil leakage.

•  If there is oil leakage, repair or replace the applicable part.

21.  Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [MZR 2.0 DISI].)

22.  Inspect for the ignition timing and idle speed. (See ENGINE TUNE-UP [MZR 2.0 DISI].)

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1	Oil pan (See Oil Pan Removal Note.) (See Oil Pan Installation Note.)

Oil Pan Removal Note

1.  Remove the oil pan using a separator tool.

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Oil Pan Installation Note

Caution

•  Apply the silicon sealant in a single, unbroken line.

•  Install the oil pan before the applied sealant starts to harden.

•  Using bolts with the old seal adhering could cause cracks in the cylinder block.

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1.  Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the cylinder block and oil pan.

2.  When reusing the oil pan installation bolts, clean any old sealant from the bolts.

3.  Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in the figure.

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4.  Install the oil pan to the cylinder block.

5.  Use a square ruler to align the oil pan and the cylinder block junction side on the engine front cover side.

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6.  Tighten the bolts in the order shown in the figure.

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7.  Tighten the oil pan-transaxle installation bolts.

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