Oil Pan: Service and Repair

Removal

WARNING:
^ Place the vehicle on a flat and solid surface.
^ Place chocks in front of and behind the rear wheels.
^ You should not remove the oil pan until the exhaust system and cooling system have completely cooled off. Otherwise, you may burn yourself and a fire could break out in the fuel line.
^ When removing the front and rear engine mounting bolts and nuts, lift the engine slightly to ensure safety.

CAUTION:
^ In lifting the engine, be careful not to hit against any adjacent parts, especially the accelerator wire casing end, brake tube and brake master cylinder.

1. Remove the undercover.
2. Drain the engine oil.
3. Remove the stabilizer bracket bolts (RH & LH).
4. Remove the front propeller shaft from front differential carrier.
5. Remove the front drive shaft fixing bolts.
6. Remove the front differential carrier bleeder hose.
7. Remove the front suspension cross member.
8. Remove the differential front mounting bolts and rear mounting bolts.
9. Remove the front differential carrier.
10. Remove the front differential carrier mounting bracket.
11. Remove the starter motor.
12. Remove the transmission to rear engine mounting bracket nuts.
13. Remove the engine mounting bolts or nuts.
14. Remove the power steering gear mounting brackets.
15. Lift up the engine. If necessary, disconnect exhaust tube.
16. Remove the relay rod. It is not necessary to disconnect pitman arm.





17. Remove the oil pan bolts in numerical order as shown.
18. Remove the oil pan.





a. Insert Tool between the cylinder block and the oil pan and tap (1) using a plastic hammer to separate the pan from the engine block, as shown.

CAUTION:
^ Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged.
^ Do not insert screwdriver, or oil pan flange will be deformed.

b. Slide Tool by tapping on the side (2) with a hammer to remove the oil pan from the engine block.

Installation





1. Before installing the oil pan, remove all traces of the liquid gasket from the mating surface using a scraper as shown.
^ Also remove all traces of liquid gasket from the mating surface of the cylinder block.





2. Apply the liquid gasket to the oil pump gasket and rear oil seal retainer gasket.
3. Apply a continuous bead of liquid gasket to mating surface of oil pan.





^ Use Genuine Silicone RTV Sealant or equivalent.





^ Be sure the liquid gasket bead is 3.5 - 4.5 mm (0.138 - 0.177 inch) wide. Apply the liquid gasket to the oil pan, going around the bolt holes as shown.





4. Install the oil pan, and tighten the oil pan bolts to specification and in the numerical order as shown.
^ Installation of the oil pan must be done within 5 minutes of the liquid gasket application.
^ Wait at least 30 minutes before filling the engine with oil.
Oil pan bolts: 6.3 - 8.3 Nm (0.64 - 0.85 kg-m, 55.6 - 73.8 inch lbs.)

5. Install the remaining components in the reverse order of removal.