Removing
1. Remove the lower oil pan.
2. Remove the oil cooler and oil filter.
Note. For correct installation, apply alignment marks to the oil cooler and upper oil pan during assembly.
3. Remove the engine front cover, drive chains and related parts.
4. Remove the dipstick from the guide.
5. If necessary, remove the engine oil level sensor.
Attention. Do not drop or subject the engine oil level sensor to impact.
6. Remove the upper oil pan:
Loosen the mounting bolts in the reverse order to that shown in the figure.
The arrow points towards the front of the engine
Insert a screwdriver into the places indicated by the black arrows in the figure and, using it as a lever, separate the upper oil pan and cylinder block.
The arrow points towards the front of the engine
Attention. Sealant has been applied in some places to meet certain operational needs and does not need to be removed, so the sealant only needs to be cut at the points shown in the figure.
Insert a special knife for sealant (KV10111100) between the upper oil pan and the cylinder block and, moving it with a hammer, cut the sealant layer.
Attention. Be careful not to damage the contact surfaces.
7. Remove the sealing ring between the cylinder block and the upper oil pan.
Installation
1. Using a scraper (A), remove the old sealant from the contact surfaces of the upper oil pan and cylinder block, as well as from the bolt holes and threads.
Attention. Be careful not to scratch or damage the contact surfaces when removing the old sealant.
2. Use a special gun to apply a continuous bead of sealant (WITH), as it shown on the picture
1. Upper part of the oil pan.
A. 2 mm outward protrusion.
H. 2 mm protrusion towards the rear oil seal.
The white arrow points towards the front of the engine.
The black arrow points outward.
Note. Use original sealant or equivalent.
Attention.
- Apply sealant to the outside of the bolt holes at the marked «A» places.
- Installation must be completed within five minutes of sealant application.
3. Install the sealing ring on the side of the cylinder block, being careful to install it correctly.
4. Tighten the bolts in the sequence shown in the figure.
The arrow points towards the front of the engine
5. Install the rear oil seal:
Attention.
- The installation of the rear oil seal must be completed within five minutes of installing the upper oil pan.
- Always replace the engine rear oil seal with a new one.
- Do not touch the seal edges.
Use a scraper to remove the protruding sealant from the mounting surfaces of the rear oil seal on the upper oil pan and cylinder block.
Apply engine oil to the outer surfaces of the rear oil seal.
Press in the rear oil seal using a suitable drift (A) with an outer diameter of 115 mm and an inner diameter of 90 mm.
Note. Press the oil seal to the depth indicated in the figures.
Check after installation
1. Check and, if necessary, adjust the engine oil level.
2. Start the engine and check for oil leaks.
3. Stop the engine and wait ten minutes.
4. Check the engine oil level again.