Upper

OIL PAN (UPPER) AND OIL STRAINER

EM-100 Exploded View:

AWD: Disassembly and Assembly

REMOVAL

CAUTION:
Never drain engine oil when the engine is hot to avoid the danger of being scalded.

1. Remove oil level gauge, oil pressure switch and oil temperature sensor.
2. Remove oil filter bracket.
3. Remove oil pan (lower).
4. Remove oil strainer.





5. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove.
<---: Engine front
^ Insert the seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper).

CAUTION:
^ Be careful not to damage the mating surfaces.
^ Never insert a screwdriver, this will damage the mating surfaces.





6. Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3).
<---: Engine front





7. Remove axle pipe, as necessary.
^ Remove axle pipe from oil pan (upper) using a suitable drift (A) [outer diameter: 37 mm (1.46 in)].

INSTALLATION








1. Install axle pipe (3) to oil pan (upper), if removed.
^ Lubricate O-ring groove of axle pipe, O-rings (1), (2), and O-ring joint of oil pan with new engine oil.





^ Install axle pipe (1) to oil pan (upper) from axle pipe flange side (left side) using a suitable drift (A) [outer diameter: 43 to 57 mm (1.69 to 2.24 in)].

CAUTION:
Insert it with care to prevent O-ring from sliding.

2. Install oil pan (upper) as follows:





a. Use a scraper (A) to remove old liquid gasket from mating surfaces.

CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.

^ Also remove old liquid gasket from mating surface of lower cylinder block.
^ Remove old liquid gasket from the bolt holes and threads.





b. Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3).
<---: Engine front





c. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure.
a: [diameter] 4.0 - 5.0 mm (0.157 - 0.197 in)
<---: Engine front
Use Genuine RTV Silicone Sealant or equivalent.

CAUTION:
^ For bolt holes with [triangle] marks (7 locations), apply liquid gasket outside the holes.
^ Attaching should be done within 5 minutes after coating.

d. Install oil pan (upper).

CAUTION:
Install avoiding misalignment of O-rings.





^ Tighten mounting bolts in numerical order as shown in the figure.
<---: Engine front
^ There are three types of mounting bolts. Refer to the following for locating bolts.
M8 x 25 mm (0.98 in): 3, 6, 8, 9, 11, 12, 14, 15, 16
M8 x 50 mm (1.97 in): 2
M8 x 90 mm (3.54 in): 1, 4, 5, 7, 10, 13
3. Install oil strainer to oil pump.
4. Install oil pan (lower).
5. Install oil pan drain plug.
^ Refer to the figure of components of former page for installation direction of drain plug washer.
6. Install in the reverse order of removal after this step.

NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.

AWD: Inspection

INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.

INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection". Testing and Inspection
2. Start engine, and check there is no leakage of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "Inspection". Testing and Inspection