Oil Pan

Removal & Installation

2.0L Engine

To Remove:

1. Remove the under cover.
2. Drain the engine oil.
3. Remove the front exhaust pipe.
4. Remove the lower oil pan. Use a block of wood and hammer to break the seal.

NOTE: Note the locations of the oil pan bolts. Not all of the bolts are the same length.

5. Remove the upper oil pan. Pry between the rear of the oil pan and engine block to remove the pan.

To Install:

1. Remove the old sealant from the engine oil pan and cylinder block sealing surfaces.
2. Apply a bead of sealant to the oil pan flange and install the oil pan. Install the pan within 15 minutes of sealant application. Make sure to install the bolts in the correct locations.

Lower oil pan bolt torque sequence (2.0L)

3. Install the lower oil pan and tighten the bolts in the sequence shown.

CAUTION
Wait at least 1 hour for the sealant to cure before adding oil and starting the engine.

4. Install the under cover.
5. Add the correct amount of engine oil to the engine.

2.0L Turbo Engine

To Remove:

1. Remove the under cover.
2. Drain the engine oil.
3. Remove the front axle crossmember bar.
4. Remove the front exhaust pipe.
5. Remove the starter motor.
6. Remove the flywheel housing lower front cover.
7. Remove the oil return pipe.
8. Remove the engine oil cooler return hose.

NOTE: Note the locations of the oil pan bolts. Not all of the bolts are the same length.

9. Remove the oil pan. Use a seal cutter to separate the oil pan from the engine block.

To Install:

1. Remove the old sealant from the engine oil pan and cylinder block sealing surfaces.
2. Apply a bead of sealant to the oil pan flange and install the oil pan. Make sure to install the pan within 15 minutes of sealant application.
3. Install the engine oil cooler return hose.
4. Install the oil return pipe.
5. Install the flywheel housing lower front cover.
6. Install the starter motor.
7. Install the front exhaust pipe.
8. Install the front axle crossmember bar
9. Install the under cover.

CAUTION
Wait at least 1 hour for the sealant to cure before adding oil and starting the engine.

10. Add the correct amount of engine oil to the engine.

2.4L Engine

To Remove:

1. Remove the side under cover.
2. Drain the engine oil.
3. Remove the front exhaust pipe.
4. Remove the torque converter housing front lower cover.
5. Remove the engine oil pan drain plug gasket.
6. To remove the engine oil pan, do the following:
   • Step 1: Remove the engine oil pan mounting bolts.

   Oil pan locations

   CAUTION
   Using the oil pan cutter #MD998727 in area "X" on the engine oil pan may cause the aluminum front case to deform.

   • Step 2: Tap the oil pan cutter special tool #MD998727 in the range of area "Y" between the cylinder block and the engine oil pan, then slide the tool sideways.

   NOTE: If you find that any sounding parts interfere with the removal, you do not need to use the oil pan cutter #MD998727.

   • Remove the engine oil pan.
7. Remove the engine oil pan strainer and gasket.
8. Remove the baffle plate.

To Install:

1. Install the baffle plate.
2. Install the engine oil pan strainer gasket.
3. Install the engine oil pan strainer.
4. To install the engine oil pan, do the following:
   • Step 1: Remove the sealant from the engine oil pan, front case, and cylinder block surfaces.

   Oil pan sealant placement

   • Step 2: Apply an even bead of sealant to the cylinder block mating surface of the engine oil pan as seen in the illustration. The manufacturer recommends using 3M™ AAD part #8672, 8704, 3M™ AAD part #8679/8678 or an equivalent.

   NOTE: Be sure to install the engine oil pan within 15 minutes after applying the sealant.

   • Step 3: Assemble the engine oil pan to the cylinder block.

   CAUTION
   Wait at least 1 hour for the sealant to cure before adding oil and starting the engine.

   • Step 4: Tighten the engine oil pan mounting bolts to 80 in-lbs (9.0 Nm). When installing the engine oil pan mounting bolts (M6 x 8 mm), note that they have different lengths from the other bolts.
5. Be sure to replace the drain plug gasket with a new one. Install the new gasket with the open side facing the engine oil pan side.
6. Install the engine oil pan drain plug.
7. Install the torque converter housing front lower cover.
8. Add the correct amount of engine oil to the engine.