Oil Pan: Service and Repair

REMOVAL
1. Remove air cleaner assembly and air ducts.
2. Disconnect the accelerator and Throttle Valve (TV) cable from the carburetor. Remove the accelerator mounting bracket.
3. Remove the fan shroud retaining bolts and position the shroud over the fan.
4. Disconnect the wiper motor electrical connector, and remove the wiper motor.
5. Disconnect the windshield washer hose.
6. Remove the wiper motor mounting cover.
7. Remove the dipstick.
8. Remove the dipstick tube retaining bolt at the exhaust manifold.
9. Remove the Thermactor crossover tube at the rear of the engine.
10. Raise the vehicle.
11. Drain the crankcase.
12. Remove the filler tube and drain the transmission.
13. Disconnect cable from starter motor, and remove starter.
14. Remove fuel line.
15. Disconnect the inlet pipes from the exhaust manifolds.
16. Remove the exhaust gas oxygen sensor.
17. Remove the Thermactor secondary air tube to torque convertor housing clamps.
18. Remove the convertor inspection cover.
19. Disconnect the exhaust pipes to catalytic convertor outlet.
20. Remove the catalytic convertor secondary air tube and inlet pipes to exhaust manifolds.
21. Loosen the engine rear mount attaching nuts.
22. Remove the engine mount through bolts.
23. Remove the shift crossover bolts at the transmission.
24. Remove the brake line retainer from the front crossmember.
25. Disconnect the transmission kickdown rod.
26. Position a jack under the engine and raise it carefully as high as it will go.
27. Place a wood block between each engine mount and the chassis brackets. When the engine is definitely secured with the wood blocks, remove the jack.
28. Remove the oil pan retaining bolts and lower the oil pan.
29. Remove the bolts retaining the oil pump pickup tube to the pump, and the nut retaining the tube to the main bearing cap. Allow the pickup tube to drop into the oil pan.
30. Rotate the crankshaft as necessary to remove pan from the vehicle.
31. Clean the oil pan and pickup tube and inspect for damage.
32. Clean the oil pan gasket surface on the cylinder block.

INSTALLATION
1. Install a new oil filter.
2. Position a new oil pan gasket on the cylinder block.
3. Place the oil pickup tube and screen assembly in the oil pan. Position the pan on the number 2 crossmember.
4. Install the oil pickup tube and screen assembly with new gasket. Tighten the bolts to 16-24 Nm (12-18 ft lb).
5. Position the oil pan and tighten the four end bolts to 12.2-15 Nm (108-132 in lb). Tighten the rest of the bolts to 9.5-12.2 Nm (84-108 in lb).
6. Position a jack under the engine, and raise enough to remove the wood blocks.
7. Lower the engine and remove the jack.
8. Install the engine support to chassis through bolts and tighten to 45-62 Nm (33-46 ft lb).
9. Connect the fuel line.
10. Install the torque convertor inspection cover.
11. Tighten the rear mount attaching nuts to 48-68 Nm (35-50 ft lb).
12. Install the shift crossover.
13. Position the catalytic convertors, secondary air tube, and inlet pipes to the exhaust manifolds. Install retaining nuts.
14. Install catalytic convertor outlet attaching bolts.
15. Install the secondary air tubes on the convertor housing.
16. Install the starter. Connect the cable.
17. Install the the exhaust gas oxygen sensor.
18. Lower the vehicle.
19. Install the dipstick and dipstick tube retaining bolt.
20. Connect the windshield wiper hose.
21. Install the windshield wiper motor mounting plate and the wiper motor.
22. Install accelerator cable mounting bracket. Connect accelerator and TV cables.
23. Position shroud and install retaining bolts.
24. Install Thermactor air tube to the rear of the engine.
25. Install air cleaner assembly and air ducts.
27. Fill crankcase with oil.
28. Install dipstick tube and fill transmission with fluid.
29. Start engine and cycle transmission through all gears.
30. Check for fluid leaks.
31. Top off fluid levels as necessary.