1. |
Drain the engine oil.
(Refer to Lubrication System - "Engine Oil") |
2. |
Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler") |
3. |
Remove the lower oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil
pan and lower oil pan. Cut off applied sealer and remove the lower oil
pan. 
• |
Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow. |
• |
After tapping the SST with a plastic hammer along the
direction of arrow around more than 2/3 edge of the oil pan, remove it
from the ladder frame. |
• |
Do not use the SST as a prybar.
Hold the tool in position (on the gasket line) and tap in with a light hammer. |
• |
Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan. |
|
|
1. |
Remove the engine assembly from the vehicle.
(Refer to Engine And Transmission Assembly - "Engine And Transmission Assembly") |
2. |
Attach the engine to engine stand for disassembly. |
3. |
Remove the timing chain.
(Refer to Timing System - "Timing Chain") |
4. |
Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan") |
5. |
Remove the oil pump.
(Refer to Lubrication System - "Oil Pump") |
6. |
Remove the LH/RH exhaust manifold stays.
(Refer to Intake And Exhaust System - "Exhaust Manifold") |
7. |
Remove the upper oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil
pan and sylinder block. Cut off applied sealer and remove the upper oil
pan. 
|
1. |
Install the lower oil pan (A).
(1) |
Using a gasket scraper, remove all the old packing material from the gasket surfaces. |
(2) |
Before assembling the oil pan, the liquid sealant TB 1217H
should be applied on oil pan. The part must be assembled within 5
minutes after the sealant was applied.
Bead width : 2.5mm(0.1in.)
|

• |
Clean the sealing face before assembling two parts. |
• |
Remove harmful foreign matters on the sealing face before applying sealant. |
• |
When applying sealant gasket, sealant must not protrud into the inside of oil pan. |
• |
To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. |
|
|
(3) |
Install the oil pan (A).
Uniformly tighten the bolts in several passes.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
|

|
|
2. |
After assembly, wait at least 30 minutes before filling the engine with oil. |
3. |
Install the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler") |
1. |
Install the upper oil pan.
A. |
Using a gasket scraper, remove all the old gasket meterial from the gasket surfaces. |
B. |
Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm (0.1in.)
|

• |
Clean the sealing face before assembling two parts. |
• |
Remove harmful foreign materials on the sealing face before applying sealant |
• |
When applying sealant gasket, sealant must not protrud into the inside of oil pan. |
• |
To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. |
|
|
C. |
Install the upper oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
|

|
|
2. |
Install the other parts reverse order of removal. |
Components
1. Upper oil pan2. Lower oil pan3. Drain plug4. Drain plug gasket
...
Components
1. Oil pump2. O-ring3. Oil pump sprocket4. Oil pump chain cover
...