Oil Pan: Service and Repair
Oil Pan
Special Tool(s)
Removal
1. Disconnect the battery ground cable.
2. Drain the cooling system.
3. Remove the radiator air deflector. 1 Remove the screws. 2 Remove the radiator air deflector.
4. Remove the engine air cleaner and the air cleaner outlet pipe.
5. Slide the clamp back and disconnect the upper radiator hose.
6. Disconnect the throttle body cam.
1 Disconnect the accelerator cable.
2 Disconnect the speed control actuator cable.
3 Remove the accelerator return spring.
7. Remove the accelerator cable bracket bolts and position the bracket and cables aside.
8. Disconnect the main vacuum harness.
9. Disconnect the Throttle Position (TP) sensor and Exhaust Gas Recirculation (EGR) vacuum regulator solenoid electrical and vacuum connectors.
10. Disconnect the fuel pressure regulator vacuum hose.
11. Disconnect the evaporative emission canister purge valve vacuum hose.
12. Disconnect the differential pressure feedback EGR system electrical connector.
13. Remove the nut and disconnect the brake booster vacuum tube and bracket.
14. Disconnect the fuel tubes.
15. Disconnect the Idle Air Control (IAC) electrical connector.
16. Position the exhaust manifold to EGR valve tube aside.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Position the tube aside.
17. Disconnect and remove the Positive Crankcase Ventilation (PCV) hose.
18. Remove the four bolts and remove the throttle body adapter.
19. Position the power steering reservoir aside.
^ Remove the upper bolt.
^ Remove the lower bolts.
^ Position the reservoir aside.
20. Disconnect the eight fuel injectors.
21. Disconnect and remove the eight ignition coils.
22. Remove the generator.
23. Disconnect the heater hose.
24. Position the fan shroud aside.
1 Remove the bolts.
2 Position the fan shroud aside.
25. Install the 3-Bar Engine Support Bracket on the engine using the generator mounting bolts.
26. Raise and support the vehicle.
27. Remove the drain plug and drain the engine oil.
28. Remove the RH motor mount bolt.
29. Remove the LH motor mount bolt.
30. Lower the vehicle.
31. Raise the engine using the Heavy Duty Engine Support.
32. Raise the vehicle on the hoist.
33. NOTE: Be careful when removing the off pan gasket. The oil pan gasket is reusable if it is not damaged.
Remove the oil pan bolts.
^ Position the oil pan aside to gain access to the oil pump screen and pickup tube.
34. Remove the bolts and the oil pump screen and pickup tube.
Installation
1. 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 old sealant.
Clean and inspect the mating surfaces.
2. Position the oil pan gasket, the oil pan and the oil pump screen and pickup tube together to the cylinder block.
3. 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: Install a new O-ring and lubricate with clean engine oil.
Position the oil pump screen and pickup tube and install the bolts.
4. 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 result in future off leakage.
Apply the silicone gasket and sealant at the engine front cover to cylinder block mating surface.
5. 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 result in future oil leakage.
Apply the silicone gasket and sealant at the rear oil seal retainer to cylinder block sealing surface.
6. Position the oil pan gasket.
7. Install the bolts and tighten in three stages, 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 60°.
8. Lower the vehicle.
9. Lower the engine and remove the Heavy Duty Engine Support-
10. Raise the vehicle on the hoist.
11. Install the RH motor mount bolt.
12. Install the LH motor mount bolt.
13. Install the drain plug.
14. Lower the vehicle.
15. Remove the 3-Bar Engine Support Bracket.
16. Install the generator.
17. Position the fan shroud and install the bolts.
18. Install the throttle body adapter and the four bolts.
19. Connect the heater hose.
20. Install and connect the eight ignition coils.
21. Connect the eight fuel injectors.
22. Install the power steering reservoir.
^ Position the reservoir.
^ Install the two lower bolts.
^ Install the upper bolt.
23. Install the PCV hose.
24. Install the exhaust manifold to EGR valve tube.
^ Hand-tighten the fittings.
^ Tighten the upper fitting.
^ Tighten the lower fitting.
25. Connect the IAC.
26. Connect the fuel tubes.
27. Connect the brake booster vacuum tube and bracket and install the nut.
28. Connect the differential pressure feedback EGR system electrical connectors.
29. Connect the evaporative emission canister purge valve vacuum hose.
30. Connect the fuel pressure regulator vacuum hose.
31. Connect the TP sensor electrical connector and the EGR vacuum regulator solenoid electrical and vacuum connectors.
32. Connect the main vacuum harness.
33. Install the accelerator cable bracket and the bolts.
34. Connect the throttle body cam.
1 Connect the accelerator cable.
2 Connect the speed control actuator cable.
3 Install the throttle return spring.
35. Connect the upper radiator hose and position the clamp.
36. Install the engine air cleaner and the air cleaner outlet pipe.
37. Install the radiator air deflector.
38. Connect the battery ground cable.
39. CAUTION: The off pump must be primed prior to starting the engine.
Fill the engine with clean engine oil.
40. Fill and bleed the cooling system.