Section 3.2 Oil Pan

Section 3.2
Oil Pan

Perform the following procedures for removal and installation of the oil pan.‪

Section 3.2.1
Oil Pan Removal

Remove the oil pan as follows:‪

1. Drain the engine oil. See Figure "Engine Oil Drain Plug" for location of the drain plug. Discard the drain plug seal.
   

   Figure 1. Engine Oil Drain Plug

   PERSONAL INJURY ‪
   To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling.‪

2. Using a floor jack, jack up the vehicle and place it on stands located behind the front suspension.
3. Loosen all front suspension shackle bolts.
4. Remove the front spring bolts and shock absorber bolts. Using the floor jack, lower the axle to the ground.
5. Remove the dipstick and dipstick O-ring. Discard the O-ring. See Figure "Oil Pan Removal and Installation" .
   

   1. Dipstick‪	11. Fill Tube Retainer Washer‪
   2. Dipstick O-ring‪	12. Oil Pan‪
   3. Dipstick Guide Tube‪	13. Oil Pan Gasket‪
   4. Adaptor‪	14. Oil Pan Bolt‪
   5. Adaptor Seal‪	15. Drain Plug Seal‪
   6. Oil Fill Cap‪	16. Oil Pan Drain Plug‪
   7. Oil Fill O-ring‪	17. Fill Tube Gasket‪
   8. Oil Fill Tube‪	18. Fill Tube Flatwasher‪
   9. Oil Fill Tube Retainer‪	19. Fill Tube Bolt‪
   10. Oil Fill Retainer Bolt‪

   Figure 2. Oil Pan Removal and Installation

6. Remove the connector and clamp attaching the dipstick guide tube to the oil fill tube. See Figure "Standoff Bracket (exploded view)" .
   

   1. Dipstick‪	5. Connector‪
   2. Oil Fill Cap‪	6. Dipstick Clamp‪
   3. Locknut‪	7. Oil Fill Tube Clamp‪
   4. Flatwasher‪	8. Bolt‪

   Figure 3. Standoff Bracket (exploded view)

7. Remove the dipstick guide tube, adaptor, and seal. Clean the guide tube and discard the seal. See Figure "Oil Pan Removal and Installation" .
8. Remove the oil fill tube.
   1. Remove the bolt that fastens the oil fill tube retainer to the cylinder block.
   2. Remove the oil fill bolts and washers that fasten the oil fill tube to the oil pan. Save the bolts and washers.
   3. Remove and discard the gasket on the oil fill tube. Clean the contact surfaces of the fill tube and the oil pan, removing all traces of gasket material.
   4. Clean the oil fill tube.
9. Remove the oil pan from the cylinder block.
10. Remove and discard the oil pan gasket. Save the bolts.
11. Thoroughly clean the pan. Remove all traces of gasket material from the pan and from the block.

Section 3.2.2
Oil Pan Installation

Install the oil pan as follows:‪

1. Position a new gasket on the cylinder block.
2. Install the pan on the block and tighten each oil pan bolt to 35 N·m (26 lb·ft). See Figure "Oil Pan Bolt Tightening Pattern" for the tightening pattern. When all the bolts have been tightened, go back and re-tighten the four corner bolts (positions #1 through #4).
   

   Figure 4. Oil Pan Bolt Tightening Pattern

3. Install the oil fill tube as follows: (See Figure "Installing the Oil Fill Tube and Dipstick Guide Tube" .)
   

   1. Dipstick‪	6. Dipstick Clamp‪
   2. Oil Fill Tube‪	7. Bolt‪
   3. Locknut‪	8. Oil Fill Tube Clamp‪
   4. Flatwasher‪	9. Oil Fill Tube Retainer‪
   5. Connector Bracket‪

   Figure 5. Installing the Oil Fill Tube and Dipstick Guide Tube

   1. Connect the oil fill tube clamp to the coolant inlet pipe using the oil fill tube clamp bolt. Tighten to 10 N·m (7 lb·ft).
   2. Position a new oil fill tube gasket on the oil pan. See Figure "Oil Pan Removal and Installation" .
   3. Install the three oil fill tube bolts. Tighten each bolt to 25 N·m (18 lb·ft).
   4. Tighten the oil fill tube clamp bolt to 25 N·m (18 lb·ft).
   5. Replace the O-ring in the oil fill cap. See Figure "Oil Pan Removal and Installation" .
4. Replace the adaptor seal on the adaptor. Install the adaptor on the oil pan. Tighten the adaptor to 50 N·m (37 lb·ft). See Figure "Oil Pan Removal and Installation" .
5. Install the dipstick guide tube on the adaptor and tighten it to 20 N·m (15 lb·ft).

   Note: Check the alignment between the dipstick guide tube and the oil fill tube. They must be parallel to each other.

6. Replace the O-ring on the dipstick.
7. Replace the seal on the oil drain plug. Install the oil drain plug on the oil pan. Tighten the drain plug to 80 N·m (59 lb·ft).
8. Install dipstick clamp, oil fill tube clamp, and connector bracket. Tighten to 10 N·m (7 lb·ft). See Figure "Installing the Oil Fill Tube and Dipstick Guide Tube" .

   Note: Check the alignment between the dipstick guide tube and the oil fill tube. They must be parallel to each other.

9. Tighten the connector bracket locknuts until firm.

   Note: Recheck the alignment between dipstick guide tube and oil fill tube.

10. Fill the engine oil circuit. The correct oil fill capacity is listed in Table "Lubricating Oil Capacity" .
11. Using the floor jack, raise the axle until it is in position to install the spring bolts and shock absorber bolts. Install the front suspension.
12. Tighten the shackle bolts and adjust the suspension.
13. Remove the stands and lower the vehicle to the ground.

    PERSONAL INJURY ‪
    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

14. Start the engine and check for leaks.
15. Shut down the engine. Check the oil level and add oil if necessary. See Figure "Oil Dipstick" .
    

    1. Maximum Fill Level‪

    2. Minimum Fill Level‪

    Figure 6. Oil Dipstick

    Note: Do not fill beyond the maximum fill level on the dipstick, since overfilling may result in high oil consumption.