Oil Pan: Service and Repair

OIL PAN AND OIL STRAINER

Image Symbols:

REMOVAL (LOWER)

WARNING: To avoid the danger of being scalded, do not drain engine oil when engine is hot.

1. Drain engine oil.
2. Remove oil pan (lower) as follows:





a. Loosen bolts with power tool in reverse order as shown to remove.





b. Remove oil pan (lower) using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surfaces.
^ Do not insert screwdriver, this will damage the mating surfaces.

NOTE: Slide seal cutter (1) by tapping on the side (2) of the tool with hammer.

INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.

INSTALLATION (LOWER)
1. Install oil pan (lower) as follows:





a. Use scraper to remove old liquid gasket from mating surfaces.
^ Also remove old liquid gasket from mating surface of oil pan (upper).
^ Remove old liquid gasket from the bolt holes and thread.

CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.





b. Apply a continuous bead of liquid gasket using Tool to the oil pan (lower) as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.

CAUTION: Attaching should be done within 5 minutes after coating.





c. Install oil pan (lower).
^ Tighten bolts in numerical order as shown.
2. Install oil pan drain plug.
3. Installation is in the reverse order of removal.

NOTE: At least 30 minutes after oil pan is installed, pour engine oil.

INSPECTION AFTER INSTALLATION
1. Check engine oil level and adjust engine oil.
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.

REMOVAL (UPPER)

WARNING: To avoid the danger of being scalded, do not drain engine oil when engine is hot.

1. Remove engine room cover with power tool.
2. Remove air duct and resonator assembly.
3. Drain engine oil.

CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.

4. Drain engine coolant.

CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.

5. Remove front final drive (4WD).
6. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way.
7. Remove starter motor.
8. Disconnect A/T fluid cooler tube brackets and position out of the way.
9. Remove oil filter, as necessary.
10. Remove oil cooler.
11. Remove oil pan (lower).
12. Remove oil strainer.
13. Remove transmission joint bolts which pierce oil pan (upper).
14. Remove rear cover plate.





15. Loosen bolts with power tool in reverse order as shown to remove.





^ Insert Tool between oil pan (upper) and lower cylinder block. Slide Tool by tapping on the side of Tool with hammer. Remove oil pan (upper).
Tool number: KV10111100 (J-37228)

CAUTION: Be careful not to damage mating surfaces.





16. Remove O-rings from bottom of lower cylinder block and oil pump.

INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.

INSTALLATION (UPPER)
1. Install oil pan (upper) as follows:





a. Use scraper to remove old liquid gasket from mating surfaces.
^ Also remove the old liquid gasket from mating surface of lower cylinder block.
^ Remove old liquid gasket from the bolt holes and threads.

CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.





b. Install new O-rings on the bottom of lower cylinder block and oil pump.





c. Apply a continuous bead of liquid gasket using Tool to the lower cylinder block mating surfaces of oil pan (upper) to a limited portion as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.

CAUTION:
^ For bolt holes with mark, apply liquid gasket outside the hole.
^ Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 inch) in diameter to area "A".
^ Attaching should be done within 5 minutes after coating.





d. Install oil pan (upper).

CAUTION: Install avoiding misalignment of both oil pan gaskets and O-rings.

^ Tighten bolts in numerical order as shown.
^ There are two types of bolts. Refer to the following for locating bolts.
M8 � 100 mm (3.97 inch): 7, 11, 12, 13
M8 � 25 mm (0.98 inch): Except the above
e. Tighten transmission joint bolts.
2. Install oil strainer to oil pan (upper).
3. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION
1. Check engine oil level and adjust engine oil.
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.