Oil Pan: Service and Repair

1. Disconnect battery ground cable, then insulate cable end with electrical tape or equivalent.
2. Remove engine oil level dipstick, then raise and support vehicle.
3. If equipped with low oil level sensor, remove electrical connector retainer clip at sensor an disconnect connector.
4. Drain engine oil.
5. Remove starter motor as follows:
a. Disconnect starter cable and push on connector from starter solenoid.

NOTE: When disconnecting the plastic hard-shell connector at "S" terminal, grasp the plastic shell, depress the tab and pull lead off. Do not pull separately on wire. Be careful to pull straight off to prevent damage to the "S" solenoid terminal.

b. Remove upper starter retaining bolt, then lower bolt and starter assembly.
6. Disconnect oxygen sensor electrical connectors.
7. Remove exhaust pipe and catalyst assembly from engine.
8. On models equipped with automatic transaxle, remove torque converter access cover from transaxle.
9. On models equipped with manual transaxle, remove left and right transaxle support plates.
10. Remove oil pan retaining bolts. Ensure internal pan baffle does not snag on oil pump pickup tube and screen when lowering pan.
11. Remove oil pan gasket and discard.
12. Remove oil pump retaining bolt, then oil pump from main bearing cap.

NOTE: When oil pump is removed, the intermediate shaft which drives the distributor will remain in the pump. If replacing the pump, remove intermediate shaft by pulling it from the pump. Check retaining clip for damage, replace if necessary.

13. Insert oil pump intermediate shaft assembly into hex drive hole in oil pump assembly until retainer clicks into place.
14. Install oil pump assembly with intermediate shaft through intermediate shaft hole in rear main bearing cap, then position pump over locating pins.
15. Install oil pump retaining bolt, then torque to 30-40 ft lb.
16. Install a new oil pan gasket on cylinder block using retaining features and gasket/trim adhesive part No. D7AZ-19B508-AA, or equivalent. Snug retaining bolts at all four corners and two places on cylinder block sealing rail to support unit until adhesive cures.
17. Apply a 3/16 inch bead of silicone sealer part No. E8AZ-19562-A, or equivalent, to the junction of the rear main bearing cap and cylinder block.
18. Apply a 3/16 inch bead of silicone sealer part No. E8AZ-19562-A, or equivalent, to the junction of the front cover assembly and cylinder block.
19. Remove bolts retaining gasket to cylinder block, then position oil pan and install retaining bolts and hand tighten.
20. Torque four corner bolts to 7-10 ft lb, then install and tighten remaining bolts.
21. Install left and right transaxle plates on manual transaxles or access plate on automatic transaxles.
22. Install starter motor assembly. Torque retaining bolts to 16-19 ft lb.
23. Connect oil level sensor connector, then install retainer clip.
24. Fill crankcase with oil.
25. Replace oil level dipstick, then connect battery ground cable.
26. Check vehicle for leaks.