Oil Pan: Service and Repair

Removal
1. Disconnect the cable from the battery negative terminal.
2. Remove the air cleaner assembly including the air intake duct.
3. Remove the fan shroud attaching bolts and position the shroud back over the fan.
4. Remove the oil level dipstick.
5. Remove the screws attaching the vacuum solenoids to the dash panel. Lay the solenoids on the engine without disconnecting the vacuum hoses or electrical connectors.
6. Raise the vehicle.
7. Remove the exhaust manifold to exhaust pipe attaching nuts.
8. Drain the crankcase.
9. Remove the oil filter.
10. Remove the bolts attaching the shift linkage bracket to the transmission bellhousing.
11. Disconnect the transmission cooler lines at the radiator.
12. Remove the four (4) converter cover retaining bolts and remove the cover.
13. Remove the nut and washer assembly attaching the front engine insulator to the chassis.
14. Raise the engine 2-3 inches and insert wood blocks between the engine mounts and the vehicle frame.
15. Remove the oil pan attaching bolts. Work the oil pan loose and remove.
16. Remove the oil pan seal from the main bearing cap. Discard the seal.

Installation

NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

1. Clean the gasket surfaces on the cylinder block, oil pan, and oil pick-up tube.
2. Trial fit the oil pan to the cylinder block. Make sure enough clearance has been provided to allow the oil pan to be installed without the sealant being scraped off when the pan is positioned under the engine.
3. Remove the oil pan.
4. Install the oil pan rear seal. Using a small screwdriver, work the tabs on each end of the seal into the gap between the rear main cap and cylinder block. With the tabs positioned work the edge of the seal into the seal groove in the rear main cap.
5. Install the oil pan as follows:
a. Apply a 3.0-4.O mm (1/8 inch) bead of Silicone Sealer D6AZ-19562-B or equivalent to the seam where the front cover and cylinder block join.
b. Apply a 3.0-4.0 mm (1/8 inch) bead of Silicone Sealer D6AZ-19562-B or equivalent to each end of the rear seal where the rear main cap and cylinder block join.
c. Apply a 3.0-4.O mm (1/8 inch) bead of Silicone Sealer along the oil pan rails on the cylinder block as the bead crosses the front cover increase the bead width to 4.0-5.O mm (1/4 inch).
d. Position the oil pan.
e. Install the oil pan attaching bolts and tighten to 9-12 Nm (80-106 in-lbs) torque.
6. Raise the engine, remove the blocks of wood supporting the engine, and lower the engine into position.
7. Install the front mount and damper (if equipped) attaching bolts and nuts.
8. Position the shift linkage bracket and install the attaching bolts.
9. Connect the transmission oil cooler lines.
10. Install a new oil filter.
11. Lower the vehicle.
12. Position the vacuum solenoids on dash panel and install the attaching screws.
13. Position the fan shroud on the radiator and install the attaching bolts.
14. Connect the battery cable.
15. Fill the crankcase to the correct level with the specified oil.
16. Start the engine and check the fluid levels in the transmission. Check for engine oil, and transmission fluid leaks.
17. Install the air cleaner assembly including air intake duct.