Oil Pan Body Assembly

Removal





1. Disconnect the battery ground cable.
Remove the battery cover.
2. Open the engine compartment and fit paintwork protection sheets.
3. Remove the engine compartment cover.
4. Remove the twin fan and motor assembly.
5. Remove the coolant outlet pipe.
6. Remove the supercharger drive belt.
7. Remove the supercharger drive belt idler pulley.





8. Remove the supercharger idler pulley mounting bracket.
Remove the three bolts which secure the mounting bracket.
Remove the mounting bracket.
9. Remove the supercharger drive belt tensioner.
10. Remove the timing cover and all associated components.
11. Remove both front wheel and tire assemblies.
12. Remove the undertray.





13. Remove the two bolts which secure the generator cooling duct to the oil pan body and remove the duct.
14. Remove the front cross member for access.





15. Drain the engine oil.
Position the waste oil dowser.
Remove the drain plug from the oil pan and drain the engine oil.
Fit a new sealing washer to the drain plug.
Wipe the drain plug and install it to the oil pan to prevent oil dripping.
Move the oil Dowser away from the vehicle.





16. Remove the oil pan.
Remove the eighteen bolts which secure the oil pan to the oil pan body.
Remove the oil pan.
Remove the casket from the oil Dan body assembly.





17. Disconnect the oil cooler pipes.
Remove the bolt which secures the oil cooler pipes.
Disconnect the oil cooler pipes from the oil pan body assembly.
Remove and discard the O-ring seals from the pipes and install blanking plugs to the pipes and unions.





18. Remove the oil filter and the oil pressure transmitter.





19. Remove the crankshaft position sensor.
Remove the bolt which secures the crankshaft position sensor to the flywheel housing.
Remove the access grommet from the housing.
Remove the sensor and allow it to hang free under the engine.
Release the harness clips from the oil pan body.





20. Remove the bolt which secures the transmission cooler pipes and remove the clamping bracket.





21. Release the air conditioning compressor.
Remove the lower securing bolts.
Loosen, but do not remove, the upper securing bolts.
Release the compressor from the lower dowel.





22. Remove the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.





23. Remove the oil pick-up pipe.
Remove the bolts which secure the pipe.
Remove the pipe.
Remove and discard the seal.





24. Remove the diverter valve.
Remove the bolts which secure the valve.
Remove the valve.
Remove and discard the O-ring seal.





25. Remove the bolts, ten outer and six inner, which secure the oil pan body.
Remove the oil pan body.





26. Remove the eight screws and release the windage tray.





27. Remove the oil filter adapter.
28. Clean all components and relevant mating faces; cylinder block, oil pan, oil pan body, windage tray, oil pick-up pipe, diverter valve and timing cover.

Installation





1. Reposition the windage tray and install the eight screws, tighten to 5 - 7 Nm.





2. Install the oil filter adapter and tighten to 26 - 34 Nm.





3. Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm diameter, around the bed plate flange OR around the oil pan body flange; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.





4. Apply a continuous bead of RTV sealant (Loctite 5699) 2 mm diameter, around the oil pick-up pipe and the diverter valve flanges; as indicated.
It is important that the oil pan body is bolted to the bedplate within twenty minutes of applying the RTV sealant.





5. Position and align the oil pan body to the bedplate.
Install the sixteen bolts and tighten to 20 - 22 Nm in the sequence indicated.





6. Install the oil diverter valve.
Install a new O-ring seal to the diverter valve.
Lubricate the O-ring seal with clean engine oil and install the valve into the oil pan body.
Install and tighten the bolts to 11 - 13 Nm.





7. Install the oil pick-up pipe.
Install a new O-ring seal to the pick-up pipe.
Lubricate the O-ring seal with clean engine oil and install the pipe to the oil pan body.
Install and tighten the bolts to 11 - 13 Nm.





8. Install the oil pan gasket to the oil pan body assembly.
Insert the seal into the locating positions in the groove, working around from a corner.
Press in the remainder of the seal, following the same procedure.





9. Install the oil pan to the oil pan body..
Position and align the oil pan.
Install, but do not tighten, all eighteen bolts which secure the oil pan.





10. Tighten the bolts to the correct torque figure 11 - 13 Nm, in the sequence indicated.
Tighten the drain plug to 30 - 40 Nm.





11. Install the oil filter and the oil pressure transmitter.
Tighten the pressure switch to 10 - 14 Nm.





12. Install the crankshaft position sensor.
Install the sensor to the flywheel housing and fit the securing bolt.
Tighten to 8 - 12 Nm.
Install the access grommet to the housing.





13. Install the four bolts (two each side) which secure the exhaust downpipes to the oil pan body.





14. Install the air conditioning compressor.
Locate the compressor onto the lower dowel.
Tighten the upper securing bolts.
Install and tighten the lower securing bolts to 18 - 24 Nm.
Tighten the upper securing bolts to 18 - 24 Nm.





15. Position the transmission cooler pipes and the clamping bracket.
Install the bolt to secure the clamp and tighten to 7 - 9 Nm.





16. Connect the oil cooler pipes to the oil pan body assembly (vehicles with engine oil cooler).
Remove the blanking plugs and install new O-ring seals.
Connect the oil cooler pipes.
Install the clamp and bolt which secures the oil cooler pipes.
Tighten to 18 - 24 Nm.
17. Install the front crossmember.





18. Position the generator cooling duct to the oil pan body and install the two bolts.
19. Install the undertray.
20. Install both front wheel and tire assemblies.
21. Install the timing cover and all associated components.
Do not refill the cooling system at this stage.
22. Install the supercharger drive belt tensioner.





23. Install the supercharger idler pulley mounting bracket.
Position the mounting bracket to the timing cover.
Install the three bolts which secure the mounting bracket.
Tighten to 8 - 10 Nm.
24. Install the supercharger drive belt idler pulley.
25. Install the supercharger drive belt.
26. Install the coolant outlet pipe.
27. Install the twin fan and motor assembly.
28. Refill the cooling system.

29. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature.

Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
Typically, 0.875 L is hung up.
Refill the engine with the correct specification engine oil.
30. Connect the battery and install the battery cover.
31. Check the oil level and start the engine.
Check for leaks and that the engine runs correctly.
32. Install the engine compartment cover.
33. Remove the paintwork protection sheets and close the engine compartment cover.