REMOVAL AND INSTALLATION


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Front Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Front Suspension Rear Crossmember Assembly Removal (Refer to GROUP 26 - Differential Carrier and Freewheel Clutch ) <4WD>.

 Post-installation Operation
  • Front Suspension Rear Crossmember Assembly Installation (Refer to GROUP 26 - Differential Carrier and Freewheel Clutch ) <4WD>.
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Under Skid Plate and Engine Room Under Cover Front Installation (Refer to GROUP 51 - Under Cover ).




Removal steps


1.
 Oil drain plug


2.
 Oil drain plug gasket
<<A>>
 >>B<<
 3.
 Oil pan lower


·
 Front differential carrier assembly (Refer to GROUP 26 - Differential Carrier and Freewheel Clutch ) <4WD>.
<<B>>
·
 Power steering gear box assembly
<<C>>
·
 Supporting the engine assembly.


4.
 Bell housing cover
<<D>>
 >>A<<
 5.
 Oil pan upper


6.
 Oil screen


7.
 Oil screen gasket

REMOVAL SERVICE POINTS

<<A>> OIL PAN LOWER REMOVAL
1.Remove the oil pan mounting bolts.

2.
caution Do not use special tool oil pan FIPG cutter (MD998727). The oil pan lower is made of aluminium and this tool will damage it.
Screw in the bolt into bolt hole A in the location shown. Then lift the oil pan and remove it.

<<B>> POWER STEERING GEAR BOX ASSEMBLY REMOVAL
1.Disconnect the steering shaft assembly and the power steering gear box assembly (Refer to GROUP 37 - Power Steering Gear Box and Linkage ).

2.Remove the mounting bolts of the power steering gear box assembly, and hung the power steering gear box assembly using a wire or other similar material (Refer to GROUP 37 - Power Steering Gear Box and Linkage ).

<<C>> SUPPORTING THE ENGINE ASSEMBLY
1.Remove the hood (Refer to GROUP 42 - Hood ).


2.Install special tool engine hanger plate (MB991956) to the cylinder head.

3.
caution Disconnect the cables, the hoses and wiring harness connectors before holding the engine assembly.
Use a chain block to hold the engine assembly. Then remove the engine mounting bolts (Refer to ).

4.Lift the engine assembly. Then insert a wooden piece (100 x 100 x 25 mm) between the engine mounting bracket (chassis frame) and the front engine support insulator.
5.Secure the engine assembly with a wooden piece to ensure working space to gain access to the oil pan upper.

<<D>> OIL PAN UPPER REMOVAL
1.Remove the oil pan mounting bolts.


2.
caution Do not use special tool oil pan FIPG cutter (MD998727). The oil pan lower is made of aluminium and this tool will damage it.
Screw in the bolt into bolt hole A in the location shown. Then lift the oil pan and remove it.

INSTALLATION SERVICE POINTS

>>A<< OIL PAN UPPER INSTALLATION
1.Remove all the traces of sealant adhering to the oil pan and cylinder block using a remover or others. Then, degrease them.

2.Apply the sealant without any gap to the mating surface of oil pan as shown in the figure, and install the oil pan to the cylinder block.
Specified sealant: ThreeBond 1217G or equivalent
note Install the oil pan immediately after applying sealant.
3.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Tighten the oil pan mounting bolts to the specified torque.
Tightening torque: 11 ± 3 N·m

>>B<< OIL PAN LOWER INSTALLATION
1.Remove all the traces of sealant adhering to the oil pan using a remover or others. Then, degrease them.

2.Apply the sealant without any gap to the mating surface of oil pan as shown in the figure, and install the oil pan to the cylinder block.
Specified sealant: ThreeBond 1217G or equivalent
note Install the oil pan immediately after applying sealant.
3.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Tighten the oil pan mounting bolts to the specified torque.
Tightening torque: 11 ± 3 N·m