Oil Pan: Service and Repair

Oil Pan





Special Tool(s)

Removal
1. Disconnect the battery ground cable.
2. Partially drain the radiator and disconnect the upper radiator hose at the radiator.
3. Remove the air cleaner outlet tube.





4. Remove the accelerator cable snow shield.





5. Disconnect the throttle body cam.
^ Disconnect the accelerator cable.
^ If equipped, disconnect the speed control cable.
^ Remove the throttle return spring.





6. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.





7. Release the idle air control (IAC) fresh air tube from the routing clip and remove it from the vehicle.





8. Disconnect the evaporative emission canister purge valve vacuum hose from the throttle body adapter.





9. Disconnect the brake booster vacuum hose and main vacuum harness from the throttle body adapter.





10. Disconnect the IAC electrical connector.





11. Disconnect the heater hose.





12. If equipped, disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector.





13. Disconnect the throttle position (TP) sensor electrical connector.





14. If equipped, disconnect the differential pressure feedback EGR system vacuum lines.





15. If equipped, disconnect the exhaust manifold to EGR valve tube fittings and remove the tube.





16. If equipped, remove the differential pressure feedback EGR system bracket.





17. If equipped, disconnect the EGR valve vacuum hose.





18. If equipped, disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.





19. Remove the throttle body adapter:
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove the throttle body adapter gasket.
20. Remove the generator.
21. Remove the two screws at the top of the fan shroud and position the fan shroud toward the engine.





22. Install the modular engine support bracket on the engine using the generator mounting holes.
23. Raise and support the vehicle.





24. Remove the engine mount nuts.

25. CAUTION: Damage to the TSS/OSS may occur and cause transmission or torque converter operational concerns if the transmission is raised prior to removing TSS/OSS.

CAUTION: Sensor bosses must be cleaned prior to removal and then plugged to prevent contamination from damaging internal components.

If the vehicle is equipped with turbine shaft speed (TSS) and output shaft sensors (OSS), remove the sensors and install plugs in the transmission.
26. Lower the vehicle.
27. Raise the engine using a floor crane attached to the support bracket.





28. Support the engine using the Heavy Duty Engine Support.
29. Raise and support the vehicle.
30. Drain the engine oil and remove the oil bypass filter.
31. Remove the dual converter Y-pipe.





32. Remove the flywheel inspection plate.





33. Install the high lift transmission jack with the special tool to the transmission.

34. CAUTION: Support the transmission on the oil pan rails only or internal transmission damage may occur.

Support the transmission with a transmission jack.

35. Remove the driveshaft.





36. Remove transmission mount nuts.
37. Raise the transmission.





38. Remove the bolts and partially lower the oil pan.





39. Remove the bolts from the oil pump screen and pickup tube and let them drop into the oil pan.





40. Remove the rear bolt and the oil pump screen and pickup tube and let them drop into the oil pan.
41. Remove the oil pan and the oil pan gasket from the rear of the engine.

42. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean the mating surfaces and thoroughly clean the oil pan.

Installation

1. NOTE: The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.

Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.





2. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low off pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.

Install the oil pump screen and pickup tube.
^ Position the oil pump screen and pickup tube on the engine.
^ Install the bolts.

3. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant where the front cover and rear crankshaft seal retainer fit to the engine block.





4. NOTE: Be sure to tighten the bolts in three stages.

Tighten the bolts in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.

5. Lower the transmission.





6. Install the transmission mount nuts.
7. Install the driveshaft.





8. Remove the high lift transmission jack and the special tool from the transmission.





9. Reinstall the transmission pan-to-case bolts that were removed to install the E40D Transmission Jack Adapter.
10. If the vehicle is equipped with turbine shaft speed and turbine/output shaft sensors, remove the plugs and install the sensors in the transmission.





11. Install the flywheel inspection plate.
12. Install the dual converter Y-pipe.
13. Install the oil bypass filter.
14. Lower the vehicle.





15. Using a floor crane, remove the Heavy Duty Engine Support.
16. Align the engine mount studs and lower the engine.
17. Remove the floor crane.
18. Raise and support the vehicle.





19. Install the engine mount nuts.
20. Lower the vehicle.





21. Remove the modular engine support bracket from the engine.
22. Install the fan shr6ud.
23. Install the generator.





24. Install the throttle body adapter.
^ Position a new throttle body adapter gasket.
^ Position the throttle body adapter.
^ Install the four bolts.





25. If equipped, connect the EGR vacuum regulator solenoid electrical and vacuum connections.





26. If equipped, connect the EGR valve vacuum hose.





27. If equipped, install the differential pressure feedback EGR system bracket.
^ Position the bracket.
^ Install the bolts.





28. If equipped, install the exhaust manifold to EGR valve tube.
^ Hand-tighten the fittings.
^ Tighten the upper fitting to 40 - 60 Nm (30 - 44 ft. lbs.).
^ Tighten the lower fitting to 40 - 60 Nm (30 - 44 ft. lbs.).





29. If equipped, connect the differential pressure feedback EGR system vacuum lines.





30. If equipped, connect the differential pressure feedback EGR system electrical connector.





31. Connect the TP sensor electrical connector.





32. Connect the heater hose.





33. Connect the IAC electrical connector.





34. Connect the brake booster vacuum hose and main vacuum harness to the throttle body adapter.





35. Connect the evaporative emission canister purge valve vacuum hose to the throttle body adapter.





36. Install the IAC fresh air tube and insert it in the routing clip.





37. Install the accelerator cable bracket.
^ Position the bracket and cables.
^ Install the bolts.





38. Connect the throttle body cam.
^ Connect the accelerator cable.
^ If equipped, connect the speed control cable.
^ Install the throttle return spring.





39. Install the accelerator cable snow shield.
40. Install the air cleaner outlet tube.
41. Connect the battery ground cable.
42. Connect the upper radiator hose to the radiator.

43. CAUTION: The oil pump must be primed prior to starting the engine.

Fill the engine with clean engine oil.
44. Fill and bleed the cooling system.