Oil Pan: Service and Repair

OIL PAN REMOVAL

1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE OIL
4. (A/T) REMOVE A/T OIL COOLER HOSE CLAMP
5. REMOVE NO.1 FRONT SUSPENSION CROSSMEMBER

6. REMOVE EXHAUST FRONT PIPE BRACKET AND STIFFENER PLATES
7. (7M-GTE) DISCONNECT ENGINE OIL COOLER HOSE FROM OIL PAN

8. REMOVE BRAKE HOSE BRACKETS AND CLIPS

9. DISCONNECT INTERMEDIATE SHAFT
Loosen the bolt, disconnect the intermediate shaft.

10. DISCONNECT STABILIZER BAR LINKS FROM LOWER ARMS
11. REMOVE ENGINE MOUNTING NUTS AND WASHERS
(a) Attach the engine hoist chain to the two engine hangers.
12 REMOVE TEMS ACTUATOR

13. REMOVE SHOCK ABSORBERS FROM BODY

14 DISCONNECT SUSPENSION MEMBER
(a) Hold the front suspension member with the jack
(b) Remove the two bolts and four nuts.

15. REMOVE OIL PAN
(a) Remove the twenty two bolts and four nuts.
(b) Using SST and a brass bar, separate the oil pan from the cylinder block. SST 09032-001000

NOTE: When removing the oil pan, be careful not to damage the oil pan flange.

INSTALL OIL PAN
(a) Remove any packing material and be careful not to drop the oil on the contacting surfaces of the oil pan and cylinder block.
- Using a razor blade and gasket scraper, remove all the packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a nonresidue solvent.

CAUTION: Do not use a solvent which will affect the painted surfaces.

(b) Apply seal packing to the cylinder block installing surface of the oil pan. Seal packing: Part No.08826-00080 or equivalent
(c) Install the oil pan over the studs on the block with the twenty two bolts and four nuts. Torque the bolts and nuts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)

1. INSTALL FRONT SUSPENSION MEMBER
(a) Install the front suspension member to the body.
Torque: 1,300 kg-cm (94 ft-lb, 127 N.m)

2. INSTALL SHOCK ABSORBERS TO BODY
Install the shock absorber to the body with the three nuts. Torque the nuts.
Torque: 360 kg-cm (26 ft lb, 35 N.m)
3. INSTALL TEMS ACTUATOR
4. INSTALL ENGINE MOUNTING WASHER AND NUTS

5. CONNECT STABILIZER BAR LINKS TO LOWER ARM
Torque: 650 kg-cm (47 ft-lb, 64 N.m)

6. CONNECT INTERMEDIATE SHAFT
Connect the intermediate shaft, torque the bolts.
Torque: 330 kg-cm (24 ft-lb, 32 N.m)

7. INSTALL BRAKE HOSE BRACKETS AND CLIPS
8. (7M-GTE) CONNECT ENGINE OIL COOLER HOSE TO OIL PAN WITH NEW GASKETS

9. INSTALL STIFFENER PLATES AND EXHAUST FRONT PIPE

10. INSTALL NO.1 FRONT SUSPENSION CROSSMEMBER
Torque: 930 kg-cm (67 ft-lb, 91 N.m)
11. INSTALL A/T OIL COOLER HOSE CLAMP
12. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with new gasket.
(b) Fill the engine with new API grade SF or SF/CC multigrade, fuel-efficient and recommended viscosity.
13. INSTALL HOOD
14. START ENGINE AND CHECK FOR LEAKS
15. INSTALL ENGINE UNDER COVER
16. INSPECTION OF FRONT WHEEL ALIGNMENT

FRONT WHEEL ALIGNMENT

1. MAKE FOLLOWING CHECKS AND CORRECT ANY PROBLEMS

(a) Check the wheel runout.
(b) Check the tires for wear and proper inflation pressure.
(c) Check the front wheel bearing for looseness.
(d) Check the front suspension for looseness.

2. MEASURE CHASSIS GROUND CLEARANCE
If the clearance of the vehicle is not standard, try to level by locking it down. If still not correct check for bad springs or suspension parts.

NOTE: Measuring point

Front Measure from the ground to the center of the lower suspension arm front mounting bolt.

Rear Measure from the ground to the center of the No.2 lower suspension arm mounting bolt.

3. INSTALL WHEEL ALIGNMENT EQUIPMENT
Follow the specific instructions of the equipment manufacturer.

4. ADJUST WHEEL ANGLE
If wheel angle differ from the standard specifications, check to see if the lengths of the left and right tie rods are the same.

NOTE: If the tie rods lengths are not equal, the wheel angle can not be adjusted properly. Reinspect the toe-in after adjusting the tie rods lengths.

5. ADJUST CAMBER, CASTER AND STEERING AXIS INCLINATION
Camber:
Inspection standard -0°05' ± 45'
Adjustment standard -0°05' ± 130'
Left-right error 30'
Caster:
Inspection standard 7°30' ± 45'
Adjustment standard 7°30' ± 30'
Left-right error 30'
Steering axis inclination:
Inspection standard 10°50' ± 45'
Left-right error 30'
If the steering axis inclination is not as specified, after camber and caster have been correctly adjusted, recheck the steering knuckle front wheel for bearing or looseness.

If camber and caster are not within specification, adjust by front and rear adjusting cams. (See adjustment chart below)
Torque: 2,450 kg-cm (177 ft-lb, 240 N.m)

NOTE Remove the stands and bounce the vehicle up and down to stabilize the suspension.

How to Read Chart
(a) Mark on the graph the measurements taken from the vehicle.
Example: Camber -0° 35'
Caster -6° 15'

(b) As shown in the illustration, read from the graph the amounts by which the front and/or rear cams are to be adjusted.

Example: Front cam Increase 1.9
Rear cam Decrease 2.7
(c) Loosen and adjust the front and/or rear cams.
(d) Torque the front and/or rear cam nuts.

Torque:
6. MEASURE TOE-IN
Measure toe-in with a toe-in gauge in the following procedure.
(a) Bounce the vehicle up and down to stabilize the pension.
(b) Move the vehicle forward about 5 m (16.4 ft) with the front wheel in the straight-ahead position on a level place.

(d) Advance the vehicle until the marks on the rear sides of the tires come to measuring heights of the gauge on the front side.

NOTE: It the tire rolls too far, repeat from step (b).

(e) Measure the distance between the marks on the front of the tires.
Inspection standard: 0 + 2 mm (0 ± 0.08 in.)
If necessary adjust the toe-in.

7. ADJUST TOE-IN
(a) Remove the boot clips.
(b) Loosen the tie rod end lock nuts.

(c) Turn the left and right tie rod ends an equal amount to adjust the toe-in.
Adjustment standard: 0 ± 1 mm (0 1 0.04 in.)

NOTE: Insure that the lengths of the left and right tie rods are the same.

Tie rod end length left-right error:
Less than 1.5 mm (0.059 in.)

(d) Torque the tie rod end clamp nuts.
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
(e) Place the boot on the seat and clamp it.

NOTE: Insure that the boots are not twisted.

8. INSPECT SIDE SLIP
Side slip limit:
Less than 3.0 mm/m (0.118 in./3.3 ft)
If the side slip exceeds the limit, the toe-in or other front wheel alignment may not be correct.