ES300 1992-1997

Oil Pan

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Removal & Installation



Specific to:

Lexus ES300 1992-1996

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the hood assembly.
  4.  
  5. Drain the coolant.
  6.  
  7. Drain the engine oil.

    Click image to see an enlarged view

    Fig. Oil pan and related components-1992-93 models



    Click image to see an enlarged view

    Fig. Oil pan and related components-1996 models, other models similar

  8.  
  9. Remove the front exhaust pipe.
    1. Loosen the two bolts, and disconnect the bracket.
    2.  
    3. Remove the two bolts and nuts holding the front exhaust pipe to the catalytic converter.
    4.  
    5. Remove the four nuts holding the front exhaust pipe to the exhaust manifolds.
    6.  
    7. Remove the front exhaust pipe and gaskets.

      Click image to see an enlarged view

      Fig. Remove the front exhaust pipe

    8.  

  10.  
  11. Remove the stiffener plate and dust seal.

    Click image to see an enlarged view

    Fig. Remove the stiffener plate

  12.  
  13. Remove the oil pan:
    1. Remove the fifteen bolts and four nuts.

      Click image to see an enlarged view

      Fig. Remove the oil pan nuts and bolts

    2.  
    3. Insert the blade of SST (SST 09032-00100) or equivalent tool between the cylinder block and oil pan, cut off the applied sealer and remove the oil pan.
      WARNING
      Be careful not to damage the flanges of the oil pan and baffle plate.

    4.  

  14.  
  15. Remove any old packing or sealer from the mounting surfaces.
  16.  

To install:

  1. Remove any old packing or sealer from the mounting surfaces. Clean all the sealing surfaces.
    WARNING
    Do not use a solvent which will affect the painted surfaces.

  2.  
  3. Apply sealant to the oil pan.
  4.  
  5. Install a nozzle that has been cut to a 0.12-0.16 in. (3-4 mm) opening.
    NOTE
    Avoid applying an excessive amount to the surface. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.



    Click image to see an enlarged view

    Fig. Oil pan sealant application-1992-93 models



    Click image to see an enlarged view

    Fig. Lower oil pan sealant application-1994-96 models

  6.  
  7. Install the oil pan with the fifteen bolts and four nuts. Tighten the oil pan mounting bolts to 65 inch lbs. (6 Nm).
  8.  
  9. Install the dipstick.
  10.  
  11. Install the dust seal to the stiffener plate.
  12.  
  13. Install the stiffener plate and tighten the mounting bolts to:

    12mm bolts: 13 ft. lbs. (18 Nm)
     
    14mm bolts: 27 ft. lbs. (37 Nm)
     

  14.  
  15. Install the front exhaust pipe:
    1. Place three new gaskets on the front pipe.
    2.  
    3. Install the front pipe with the two bolts and six nuts. Torque the nut:

      To manifold: 46 ft. lbs. (62 Nm)
       
      To converter: 32 ft. lbs. (43 Nm)
       

    4.  
    5. Connect the bracket with the two bolts.
    6.  

  16.  
  17. Refill the fluids.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start engine and check for leaks.
  22.  
  23. Recheck engine coolant and engine oil levels.
  24.  
  25. Install the hood.
  26.  

Specific to:

Lexus ES300 1997-1999

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the front of the vehicle.
  4.  
  5. Remove the right front wheel.
  6.  
  7. Remove the fender apron seal.
  8.  
  9. Remove the engine undercover.
  10.  
  11. Drain the engine oil from the engine.
  12.  
  13. Remove the front exhaust pipe.
  14.  
  15. Remove the front exhaust pipe bracket from the No. 1 oil pan.
  16.  
  17. Remove the alternator drive belt from the engine.
  18.  
  19. Remove the A/C compressor from the engine.
  20.  
  21. Remove the power steering pump drive belt and adjusting strut.
  22.  
  23. Remove the timing belt from the engine.
  24.  
  25. Remove the timing belt pulleys.
  26.  
  27. Remove the rear timing belt cover from the engine by removing the wire clamps and six bolts.
  28.  
  29. Remove the A/C compressor housing bracket.
  30.  
  31. Remove the ten bolts, two nuts and the No. 2 oil pan.

    Click image to see an enlarged view

    Fig. Remove the No. 2 oil pan

  32.  
  33. Insert the blade of SST tool 09032-00100 or equivalent between the No. 1 and No. 2 oil pans. Remove the No. 2 oil pan from the engine. Clean the surfaces of the oil pans.

    Click image to see an enlarged view

    Fig. Use the special tool to break the seal and remove the oil pan

  34.  
  35. Remove the oil strainer and gasket from the engine.

    Click image to see an enlarged view

    Fig. Remove the oil strainer

  36.  
  37. Remove the No. 1 oil pan:
    1. Remove the bolts and flywheel housing under cover.
    2.  
    3. Remove the exhaust pipe support stay, as applicable.
    4.  
    5. Remove the 17 bolts and 2 nuts.

      Click image to see an enlarged view

      Fig. Remove the nuts and bolts and No. 1 oil pan-1997-98 models



      Click image to see an enlarged view

      Fig. Remove the bolts and No. 1 oil pan-1999 models

    6.  
    7. Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan.
      NOTE
      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

    8.  

  38.  

To install:

  1. Install the No. 1 oil pan as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.

      Click image to see an enlarged view

      Fig. Apply sealant as shown to the No. 1 (upper) oil pan

    4.  
    5. Install the oil pan with the seventeen bolts and two nuts. Uniformly tighten the bolts and nuts in several passes.
    6.  
    7. Torque the bolts as follows:

      10mm head bolt: 69 inch lbs. (8 Nm)
       
      12mm head bolt: 14 ft. lbs. (20 Nm)
       
      14mm head bolt: 27 ft. lbs. (37 Nm)
       

    8.  
    9. Install the flywheel housing undercover with the two bolts. Torque the bolts to 69 inch lbs. (8 Nm).
    10.  

  2.  
  3. Install the oil strainer with the three nuts. Torque the nuts to 69 inch lbs. (8 Nm).
  4.  
  5. Install the No. 2 oil pan as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.
    4.  
    5. Install the No. 2 oil pan with the ten bolts and two nuts. Uniformly tighten the bolts and nuts in several passes. Torque the bolts to 69 inch lbs. (8 Nm).
    6.  

  6.  
  7. Install the oil level sensor.
  8.  
  9. Install the A/C compressor housing bracket.
  10.  
  11. Install the rear timing belt cover.
  12.  
  13. Install the timing belt pulleys.
  14.  
  15. Install the timing belt.
  16.  
  17. Install the power steering pump drive belt and adjusting strut.
  18.  
  19. Install the A/C compressor.
  20.  
  21. Install the alternator drive belt.
  22.  
  23. Install the front exhaust pipe bracket to the No. 1 oil pan.
  24.  
  25. Install the front exhaust pipe.
  26.  
  27. Install the fender apron seal.
  28.  
  29. Install the right front wheel.
  30.  
  31. Fill the engine with oil.
  32.  
  33. Connect the negative battery cable to the battery.
  34.  
  35. Start the engine and check for leaks.
  36.  
  37. Recheck the engine oil.
  38.  

 
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