Oil Pan: Service and Repair

WARNING: Normal operating temperature of exhaust system is very high. Never work around or attempt to service any part of exhaust system until it has cooled. Use special care when working around three way catalytic converter. These units heat to a high temperature after only a short period of engine operation.

1. Remove water pump pulley shield bolts from lefthand valve cover, then water pump pulley shield from vehicle.
2. Install three bar engine support D88L-6000-A, or equivalent, onto engine lifting eyes and support engine.
3. Raise and support vehicle, then remove Y pipe as follows:
a. Remove front and rear Y pipe flange fasteners from exhaust manifold, then stud bolt and nut retainer from oil pan.
b. Remove two remaining nuts and bolts from Y pipe outlet connection, then discard exhaust converter inlet gasket.
c. Remove Y pipe.
4. Remove exhaust heat shield nuts, then heat shields from lefthand side of oil pan.
5. Remove oil pan drain plug and drain engine oil from engine.
6. Install oil pan drain plug with new gasket.
7. Remove oil pan retaining bolts from transaxle housing.
8. On models equipped with automatic transaxle, remove engine rear plate access plug.
9. Remove lefthand and righthand front engine support insulator through bolt.
10. Lower vehicle, then mark location of upper front engine support bracket.
11. Remove upper front engine support bracket nuts from upper front engine support insulator.
12. Raise engine to gain access for removal of oil pan. Support engine with engine support tool.

Fig. 31 Oil pan bolt removal sequence:

13. Raise and support vehicle, then remove oil pan retaining bolts, in sequence, from lower cylinder block.
14. Remove oil pan and gasket, then discard gasket.
15. Remove oil pump screen cover and tube nut from lower cylinder block stud bolt.

Fig. 32 Oil pump screen cover and tube replacement:

16. Remove oil pump screen cover and tube bolts from oil pump, then the cover and tube from engine.
17. Reverse procedure to install, noting following:
a. Inspect oil pump screen cover and tube O-ring for damage and wear. Replace O-ring as necessary.
b. Install new self-locking oil pump screen cover and tube support nut to lower cylinder block stud. Tighten nut to 15-22 ft lb.
c. Clean oil pan with suitable soap and water solution, then dry completely with compressed air. Inspect oil pan for damage and replace as necessary.
d. Clean oil pan to lower cylinder block sealing surfaces with shop towel and suitable metal surface cleaner to remove all residues which may interfere with sealer's ability to adhere.

Fig. 33 Oil pan installation:

e. Apply a 0.31 inch diameter bead of suitable sealer on oil pan gasket, then install gasket.
f. Tighten oil pan to transaxle bolts to 25-34 ft lb.

Fig. 33 Oil pan installation:

g. Torque oil pan retaining bolts and studs in sequence to 15-22 ft lb.
h. Tighten oil pan to transaxle housing bolts to 25-34 ft lb.