Oil Pan: Service and Repair

OIL PAN

REMOVAL
1. Drain engine oil.
2. Remove the sway bar retaining bolts and swing sway bar down and out of the way.
3. Remove the wiring harness duct from the oil pan bolts and position out of the way.
4. Lower the vehicle and remove the turbocharger upper heat shield.





5. Connect engine support fixture #8534 using adaptors #853416, to the engine lifting eye and raise engine slightly (Fig. 54).
6. Remove engine mounts and raise engine.
7. Disconnect the oil level sensor.
8. Remove the transmission cooler lines from the oil pan bolts and carefully position the lines aside
9. Remove the oil pan bolts.





10. Remove oil pan and gasket (Fig. 55).

INSTALLATION





NOTE: Oil pan bolts are of different diameters and lengths. Care must be take to install the bolts in their original position (Fig. 57).

NOTE: Clean the strainer of the oil pump. If the oil pump is dry, coat the inside with clean engine oil.

NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly.

1. Slide the oil pan into position.
2. Slide the gasket into position.





3. Add sealant to the joints on the engine block where indicated (Fig. 56).
4. Install the oil pan. Tighten M6 bolts to 9 Nm (80 inch lbs.) and M8 bolts to 20 Nm (15 ft. lbs.) (Fig. 57).
5. Tighten the bolt of the transmission bell housing to oil pan to 40 Nm (30 ft. lbs.).
6. Install the wiring harness duct (Fig. 55).
7. Connect the oil level sensor (Fig. 55).
8. Lower the vehicle.
9. Lower the engine until the engine mount and engine supports make contact.
10. Start and hand tighten the engine mount bolts.
11. Lower the engine the rest of the way and remove the engine support fixture.
12. Tighten the engine mount bolts to 83 Nm (61 ft. lbs.).
13. Install the sway bar and tighten bolts to 30 Nm (22 ft. lbs.).
14. Refill crankcase with the proper engine oil to the proper level.
15. Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

16. Start the engine and inspect for leaks.