Oil Pan and Oil Pump Removal and Installation

REMOVAL AND INSTALLATION

Required Special Tools:

- MB991396: Oil Filter Wrench

- MB991614: Angle Gauge

- MD998382: Crankshaft Front Oil Seal Installer

- MD998727: Oil Pan FIPG Cutter

REMOVAL SERVICE POINTS

[[A]] OIL PAN LOWER REMOVAL

CAUTION:
To prevent the sealed area from being damaged, carefully insert the special tool.

Insert the special tool MD998727, into the groove shown in the illustration. Strike and slide it and then cut the liquid gasket.

[[B]] OIL PAN UPPER REMOVAL

1. Remove the bolts A shown in the illustration first.
2. Remove all other bolts.

CAUTION:
Do not use a scraper or special tool to remove the oil pan upper.

3. Thread the M10 x 1.25 pitch bolt into the illustrated bolt hole to remove the oil pan upper.

INSTALLATION SERVICE POINTS

]]A[[ OIL PUMP CASE INSTALLATION

1.
CAUTION:
Carefully work so that the rests of the liquid gasket cannot enter to the oil passage or water passage.

Remove the remaining liquid gasket on the oil pump case and the cylinder block.

2. Degrease and clean the plane where the liquid gasket is applied and the both sides of the chamfered areas where the liquid gasket collects.

3. After degreasing and cleaning the plane and the both sides, always spray compressed air into the oil passage and the water passage. Check that the oil passage and the water passage are free of foreign materials such as liquid gasket.

4. As shown in the illustration, apply a 2.0 ± 0.5 mm (0.08 ± 0.01 inch) diameter bead of sealant (Three bond 1217G or exact equivalent) to the area on the oil pump case.
5. After checking that the o-ring is installed at three places, install the oil pump case to the cylinder block.
6. Tighten the oil pump case to the specified torque.
Tightening torque: 23 ± 6 Nm (17 ± 4 ft-lb)

]]B[[ CRANKSHAFT FRONT OIL SEAL INSTALLATION

Using special tool MD998382, press-fit the oil seal into the oil pump case.

]]C[[ BEAM / BEARING CAP BOLT / RIGHT PLATE / LEFT PLATE INSTALLATION

1. Before installing the bearing cap bolt, check the bolt screw head is not damaged. If the screw head extremely gets damaged, replace it with a new bolt. The standard length of the new bolt measured from under the head is as follows:
Standard value: 100.7 - 101.7 mm (3.97 - 4.00 inches)

2.
CAUTION:
When the beam is removed and installed, never loosen the tightening bolts of the crankshaft bearing cap.

Put the right and left plates on the crankshaft bearing, Temporarily tighten bolt.

3. Put the beam on them, Temporarily tighten bolt.

4. Tighten the beam bolts to the specified torque in the tightening sequence shown.
Tightening torque: 24 ± 2 Nm (18 ± 1 ft-lb)

5.
CAUTION:

- When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.

- When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.

Using the special tool MB991614, tighten the beam bolt (M9) 60 degrees in accordance with the tightening order.

6. Tighten the plate bolts to the specified torque in the tightening sequence shown.
Tightening torque: 23 ± 6 Nm (17 ± 4 ft-lb)

]]D[[ OIL SCREEN GASKET INSTALLATION

Install the oil screen gasket so that the tab is positioned as shown in the illustration.

]]E[[ OIL PAN UPPER INSTALLATION

1. Clean the gasket surfaces of the oil pan upper and oil pan lower.

2.

Apply a 2.5 ± 0.5 mm (0.10 ± 0.01 inch) bead of liquid gasket to location A, and a 4.0 ± 0.5 mm (0.20 ± 0.01 inch) bead of liquid gasket to location B, and a 3.2 ± 0.5 mm (0.13 ± 0.01 inch) bead of liquid gasket to location C on the oil pan respectively as illustrated.
Specified sealant:

Three bond 1217G or equivalent
NOTE:
Install the oil pan within 15 minutes after applying liquid gasket.

NOTE:
Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.

3. Tighten the upper oil pan bolts in the sequence shown.
Tightening torque: 10 ± 2 Nm (89 ± 17 in-lb)
4. After installation, keep the sealed area away from the oil and coolant for approximately one hour.

]]F[[ OIL PAN LOWER INSTALLATION

1. Clean the gasket surfaces of the cylinder block and oil pan lower.

2. Apply a 2.5 ± 0.5 mm (0.10 ± 0.01 inch) diameter bead of sealant (Three bond 1217G or exact equivalent) to the oil pan. Be sure to install the oil pan quickly while the sealant is wet.
NOTE:
Install the oil pan within 15 minutes after applying liquid gasket.

NOTE:
Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.

CAUTION:

- The threaded part tip of the switch must be clear of the sealant.

- Use care not to allow the sealant to plug the oil passage.

1. Completely remove existing sealant from the oil pressure switch and the switch mounting hole on the oil pump case.
2. Apply sealant (Three bond 1215, Three bond 1212D or equivalent) to the threaded part of the oil pressure switch as shown.
3. Install the oil pressure switch to the oil pump case by tightening to a specified torque.
Tightening torque: 10 ± 2 Nm (89 ± 17 in-lb)

]]H[[ OIL FILTER COVER INSTALLATION

CAUTION:
Do not damage the sealed area.

Check the right and left ribs of the oil filter cover touch the outer circumference of the oil filter boss.

]]I[[ OIL FILTER INSTALLATION

1. Clean the filter mounting surface on the front case.
2. Apply engine oil to the O-ring of the oil filter.

3.
CAUTION:
If the filter is tightened by hand only, it will be insufficiently torqued, resulting in oil leaks.

Screw the oil filter in and tighten the oil filter to the specified torque using a commercially available special tool MB991396 or general tool from where the O-ring has come into contact with the oil filter mounting surface.
Tightening torque:

MD332687, MD365876 16 ± 4 Nm (13 ± 3 ft-lb) [approx.
1 turn]
MD360935 14 ± 2 Nm (124 ± 17 in-lb) [approx. 3/4 of a turn]

]]J[[ DRAIN PLUG GASKET INSTALLATION

CAUTION:
If the gasket is installed in the wrong direction, oil leaks will occur.

Install the drain plug gasket as illustrated.