Removal And Installation
OIL PAN
Removal and Installation
REMOVAL
WARNING:
- To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
- Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
1.Drain engine oil. Removal and Replacement.
2.Remove engine and transaxle assembly. Removal And Installation.
3.Remove flywheel (M/T models) or drive plate (CVT models).
4.Mount engine on suitable stand.
5.Remove oil filter using Tool.
Tool number: KV-10115801 (-)
CAUTION:
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
6.Remove the oil pan (lower) bolts in reverse order as shown.
7.After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool.
Tool number: KV-10111100 (J-37228)
- Slide (1) the Tool by tapping (2) its side with a hammer to remove the lower oil pan from the upper oil pan.
CAUTION:
Be careful not to damage the mating surfaces.
8.Remove the following parts:
- Front cover, timing chain, oil pump drive chain;
- Oil level gauge guide.
9.Remove oil pan (upper) bolts in reverse order as shown.
10.Insert a suitable tool at the position shown by the arrow (black arrow) and open up a crack between oil pan (upper) and cylinder block.
CAUTION:
The liquid gasket used at the factory is very strong. Apply pressure only in the locations shown in the illustration.
11.After removing the bolts, separate the mating surface and remove the sealant using Tool.
Tool number: KV-10111100 (J-37228)
- Slide (1) the Tool by tapping (2) its side with a hammer to remove the upper oil pan from the cylinder block.
CAUTION:
Be careful not to damage the mating surfaces.
12.Remove O-ring between cylinder block and oil pan (upper).
CAUTION:
Do not reuse O-ring.
INSPECTION AFTER REMOVAL
Oil Filter
Clean oil strainer portion (part of the oil pump) if any object attached.
INSTALLATION
1.Use a scraper (A) to remove old liquid gasket from mating surfaces.
- Remove the old liquid gasket from mating surface of cylinder block.
- Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
2.Apply the sealant without breaks to the specified location using
Tool.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants.
Tool number WS-39930000 (-)
CAUTION:
- Apply liquid gasket to outside of bolt hole for the positions shown by marks.
- The components must be installed within 5 minutes of the liquid gasket application.
- Then allow 30 minutes for the liquid gasket to set before operating the engine.
3.Install new O-ring at cylinder block side.
CAUTION:
- Install avoiding misalignment of O-ring.
- Do not reuse O-ring.
4.Tighten the oil pan (upper) bolts in numerical order as shown.
5.Install rear oil seal with the following procedure.
CAUTION:
- The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper).
- Always replace rear oil seal with new one.
- Never touch oil seal lip.
a.Wipe off liquid gasket protruding to the rear oil seal mating part of oil pan (upper) and cylinder block using a scraper.
b.Apply engine oil to entire outside area of rear oil seal.
c.Press-fit the rear oil seal using a drift with outer diameter 115
mm (4.53 in) and inner diameter 90 mm (3.54 in) (A).
- Press-fit to the specified dimensions as shown.
CAUTION:
- Never touch the grease applied to the oil seal lip.
- Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft.
- Press-fit straight, making sure that rear oil seal does not curl or tilt.
NOTE:
The standard surface of the dimension is the rear end surface of cylinder block.
6.Install oil pump sprocket, oil pump drive chain and other related parts if removed.
7.Use a scraper (A) to remove old liquid gasket from mating surfaces.
- Also remove old liquid gasket from mating surface of oil pan (upper).
- Remove old liquid gasket from the bolt holes and threads.
8.Apply the sealant (A) without breaks to the specified location using Tool.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants
Tool number WS-39930000 (-)
9.Tighten bolts in numerical order as shown.
10.Install oil filter with the following procedure:
a.Remove foreign materials adhering to the oil filter installation surface.
b.Apply new engine oil to the oil seal contact surface of new oil filter.
c.Screw oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Or tighten to specification.
Oil filter:: 17.7 Nm (1.8 kg-m, 13 ft-lb)
Tool number:: KV-10115801 (J-38956)
11.Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level..
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:
