Isuzu Cars and Trucks 1981-1991

Oil Pan

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REMOVAL AND INSTALLATION
4-Cylinder Gasoline Engines with Rear Wheel Drive

NOTE
Isuzu recommends removing the engine (or at least raising it up) to service the oil pan. There is not sufficient clearance to remove the pan with the engine bolted down.

  1. Remove or raise the engine to allow sufficient room to clear the oil pan.
  2.  


NOTE
On the 4XC1-U engine, disconnect the exhaust pipe bracket and the exhaust pipe at the manifold. Disconnect the right hand tension rod located under the front bumper to gain access to the oil pan.

  1. Remove the bolts and nuts attaching the oil pan to the engine block. Remove the oil pan and gasket.
  2.  
  3. Clean the oil pan and engine block gasket surface carefully to remove all traces of the old gasket.
  4.  



Click image to see an enlarged view

Fig. Oil pan assembly G180Z engine shown, others similar



Click image to see an enlarged view

Fig. Oil pan gasket compression

To install:

  1. Using a thin coat of Permatexand#x00AE; No. 2 or equivalent to hold the gasket in place while installing the bolts and to prevent any oil leaks.
  2.  


NOTE
If using a silicone sealant, apply the correct width bead of the sealant to the contact surfaces of the oil pan. There must be no gaps in the bead. The oil pan must be installed within 30 minutes after the sealant application

  1. Torque the all the oil pan bolts evenly. Check the edges of the gasket to ensure that it is sealed properly. If the gasket projects unevenly around the oil pan flange, remove the gasket and reinstall carefully.
  2.  


NOTE
Do not overtighten the oil pan bolts. Bolts that are too tight cause as many leaks as bolts that are too loose.

  1. Start the engine and check for leaks.
  2.  

4ZD1 and 4ZE1 Engines

NOTE
On 4WD gasoline engines, the engine must be removed before removing the oil pan.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil.
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the front splash shield, if equipped.
  2.  
  3. If equipped with a crossmember, remove it.
  4.  
  5. Disconnect the relay rod at the idler arm and lower the relay rod.
  6.  
  7. Remove the left side bellhousing bracket.
  8.  
  9. Disconnect the vacuum line from the oil pan.
  10.  
  11. Remove the oil pan bolts and remove the oil pan.
  12.  



Click image to see an enlarged view

Fig. Exploded view of the oil pan used with 4WD 4ZD1 and 4ZE1 engines

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Using a new gasket and sealant, install the oil pan. Torque the oil pan-to-engine bolts to 35 and 1951 inch lbs. (4 and 196 Nm).
  4.  
  5. Connect the vacuum line to the oil pan.
  6.  
  7. Install the left side bellhousing bracket.
  8.  
  9. Connect the relay rod at the idler arm and lower the relay rod.
  10.  
  11. If equipped with a crossmember, install it.
  12.  
  13. Install the front splash shield, if equipped.
  14.  
  15. Refill the engine oil.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the negative battery cable, start the engine and check for leaks.
  20.  

Diesel Engine
UPPER OIL PAN
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Drain the engine oil. Remove the dipstick and the dipstick tube.
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the upper oil pan-to-engine bolts and the oil pan.
  2.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Using a new gasket and sealant, install the oil pan. Torque the oil pan-to-engine bolts to 120 and 19185 inch lbs. (14 and 1918 Nm).
  4.  
  5. Install the engine into the vehicle as outlined in this Section.
  6.  
  7. Connect the battery cable, start the engine and check for leaks.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the upper and lower oil pans diesel engines

LOWER OIL PAN
  1. Raise and safely support the vehicle.
  2.  
  3. Drain the crankcase.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the lower oil pan-to-upper oil pan bolts and the lower pan.
  2.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Using a new gasket and sealant, install the lower oil pan and torque the bolts to 24 and 1996 inch lbs. (3 and 1911 Nm).
  4.  
  5. Refill the crankcase, connect the negative the battery cable, start the engine and check for leaks.
  6.  

V6 Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the dipstick. Raise and safely support the vehicle. Drain the crankcase.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the front skid plate and the crossmember.
  2.  
  3. Remove the exhaust pipe-to-catalytic converter bolts, the exhaust pipe-to-manifolds bolts and the Y-exhaust pipe.
  4.  
  5. Remove the front driveshaft from the front differential.
  6.  
  7. Remove the braces from the flywheel cover.
  8.  
  9. Disconnect the electrical connectors from the starter. Remove the starter-to-engine bolts and the starter.
  10.  
  11. Remove the flywheel inspection cover.
  12.  
  13. Matchmark the pitman arm-to-pitman shaft for reassembly. Remove the pitman arm-to-pitman arm shaft nut and separate the pitman arm from the pitman shaft.
  14.  
  15. Remove the idler arm-to-shaft nut and separate the idler arm from the shaft.
  16.  
  17. Remove the rubber hose from the front axle vent and support the axle housing assembly.
  18.  
  19. Remove both bolts from the left axle housing isolator and the right axle housing isolator, then, lower the front axle housing assembly.
  20.  
  21. Remove the oil pan-to-engine bolts, the oil pan and discard the gasket.
  22.  
  23. Clean the gasket mounting surfaces.
  24.  



Click image to see an enlarged view

Fig. Exploded view of the oil pan assembly V6 engines

To install:

  1. Using a new gasket and sealant, install the oil pan. Torque both rear pan-to-engine bolts to 18 ft. lbs. (25 Nm) and the other bolts/nuts/studs to 7 ft. lbs. (10 Nm).
  2.  
  3. To complete the installation, reverse the removal procedures. Torque the following fasteners:
  4.  
  5. Pitman arm-to-pitman shaft nut: 159 ft. lbs. (215 Nm)
  6.  
  7. Idler arm-to-shaft nut: 86 ft. lbs. (117 Nm)
  8.  
  9. Front drive axle shaft bolts: 46 ft. lbs. (62 Nm)
  10.  
  11. Refill the crankcase. Connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  

 
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