Subaru Car 1998-05

Oil Pan

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the oil pan and lubrication components-2.2L and 2.5L engines



Click image to see an enlarged view

Fig. Exploded view of the oil pan and lubrication components-2.0L turbocharged engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Mass Air Flow (MAF) sensor on turbo models
     
    Air intake boot and air cleaner upper cover on turbo models
     
    Intercooler on turbo models
     
    Front Oxygen Sensor (O2S) electrical connector
     
    Pitching stopper
     
    Upper radiator brackets
     

  4.  
  5. Support the engine with a suitable lifting device.

    Front wheel and tire assemblies
     

  6.  
  7. Lift up the engine slightly.

    Engine undercover
     

  8.  
  9. Drain the oil from the engine into a suitable container.
  10.  
  11. Install the drain plug with a new gasket and tighten it to 33-36 ft. lbs. (43-47 Nm).
  12.  
  13. Remove or disconnect the following:

    Rear O2S electrical connector
     
    Exhaust Y-pipe
     
    Nuts that secure the front engine mounts to the front crossmember
     
    Oil pan mounting bolts
     

  14.  
  15. Insert an oil pan cutter blade between the upper and lower pans, on 3.0L engines
  16.  
  17. While supporting the oil pan, use a rubber mallet and tap the oil pan to free it from the engine.
  18.  
  19. Clean all gasket material from both mating surfaces.
  20.  

To install:



Click image to see an enlarged view

Fig. Oil pan bolt torque sequence-3.0L engines

  1. Apply a continuous bead of sealer to a new oil pan gasket.
  2.  
  3. Install the oil pan assembly. Tighten the bolts to 36-48 inch lbs. (4-5 Nm) on all models except 3.0L engines. On 3.0L engines tighten the bolts to 5 ft. lbs. (7 Nm).
  4.  
  5. Lower the engine onto the front crossmember.
  6.  
  7. Install or connect the following:

    Front engine mount nuts and tighten to 61 ft. lbs. (83 Nm)
     
    Y-pipe with new gaskets. Tighten the pipe-to-engine nuts to 23 ft. lbs. (30 Nm)
     
    Rear O2S electrical connector
     
    Engine undercover
     
    Front wheel and tire assemblies
     

  8.  
  9. Remove the engine lifting device.

    Front O2S sensor electrical connector
     
    Pitching stopper. Tighten the front bolt to 40 ft. lbs. (54 Nm) and the rear bolt to 49 ft. lbs. (67 Nm).
     
    Upper radiator brackets
     
    MAF sensor on turbo models
     
    Air intake boot and air cleaner upper cover on turbo models
     
    Intercooler on turbo models
     
    Air intake duct
     
    Negative battery cable
     

  10.  
  11. Fill the engine to the proper level with the recommended oil and run the engine. Check for leaks.
  12.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Mass Air Flow (MAF) sensor on turbocharged engine
     
    Air intake boot and air cleaner upper cover on turbocharged engine
     
    Intercooler on turbocharged engine
     
    Front Oxygen Sensor (O 2 S) electrical connector
     
    Pitching stopper
     
    Upper radiator brackets
     

  2.  
  3. Support the engine with a suitable lifting device.

    Front wheel and tire assemblies
     

  4.  
  5. Lift up the engine slightly.

    Engine undercover
     

  6.  
  7. Drain the oil from the engine into a suitable container.
  8.  
  9. Install the drain plug with a new gasket and tighten it to 33-36 ft. lbs. (43-47 Nm).
  10.  
  11. Remove or disconnect the following:

    Rear O 2 S electrical connector
     
    Exhaust Y-pipe
     
    Nuts that secure the front engine mounts to the front crossmember
     
    Oil pan mounting bolts
     

  12.  
  13. Insert an oil pan cutter blade between the upper and lower pans, on 3.0L engine
  14.  
  15. While supporting the oil pan, use a rubber mallet and tap the oil pan to free it from the engine.
  16.  
  17. Clean all gasket material from both mating surfaces.

    Click image to see an enlarged view

    Fig. Oil pan and related components-2.2L and 2.5L engines



    Click image to see an enlarged view

    Fig. Oil pan and related components-2.0L engine

  18.  

To install:

  1. Apply a continuous bead of sealer to a new oil pan gasket.
  2.  
  3. Install the oil pan assembly. Tighten the bolts to 36-48 inch lbs. (4-5 Nm) on all except 3.0L engine. On 3.0L engine tighten the bolts to 5 ft. lbs. (7 Nm).
  4.  
  5. Lower the engine onto the front crossmember.
  6.  
  7. Install or connect the following:

    Front engine mount nuts and tighten to 61 ft. lbs. (83 Nm)
     
    Y-pipe with new gaskets. Tighten the pipe-to-engine nuts to 23 ft. lbs. (30 Nm)
     
    Rear O 2 S electrical connector
     
    Engine undercover
     
    Front wheel and tire assemblies
     

  8.  
  9. Remove the engine lifting device.

    Front O 2 S sensor electrical connector
     
    Pitching stopper. Tighten the front bolt to 40 ft. lbs. (54 Nm) and the rear bolt to 49 ft. lbs. (67 Nm).
     
    Upper radiator brackets
     
    MAF sensor on turbocharged engine
     
    Air intake boot and air cleaner upper cover on turbocharged engine
     
    Intercooler on turbocharged engine
     
    Air intake duct
     
    Negative battery cable
     

  10.  
  11. Fill the engine to the proper level with the recommended oil and run the engine. Check for leaks.
  12.  

1.8L Engine


Click image to see an enlarged view

Fig. Oil pan and lubrication components-1.8L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Drain the engine oil into a suitable container.
  6.  
  7. Remove the oil pan mounting bolts.
    NOTE
    It may be necessary to remove the motor mount bolts and jack up the engine slightly to remove the oil pan.

  8.  
  9. Tap the oil pan with a plastic-faced hammer to break the seal between the pan and the engine block.
  10.  
  11. Remove the oil pan from the engine, guiding it past the oil strainer.
  12.  
  13. Clean all gasket material from both mating surfaces.
  14.  
  15. Installation is the reverse of removal. Apply a bead of sealer around the lip of the oil pan and set the gasket in place on the sealer.
  16.  
  17. Position the oil pan to the engine block tighten the bolts in a cross pattern to 4 ft. lbs. (5 Nm).
  18.  
  19. Tighten the oil pan drain plug to 18 ft. lbs. (25 Nm). Refill the crankcase with oil. Start the engine and check for leaks.
  20.  

2.2L & 2.5L Engines


Click image to see an enlarged view

Fig. Exploded view of the oil pan and lubrication components-2.2L and 2.5L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Front Oxygen (O 2 S) sensor electrical connector
     
    Pitching stopper
     
    Upper radiator brackets
     

  4.  
  5. Support the engine with a suitable lifting device.

    Front wheel and tire assemblies
     

  6.  
  7. Lift up the engine slightly.

    Engine under cover
     

  8.  
  9. Drain the oil from the engine into a suitable container.
  10.  
  11. Install the drain plug with a new gasket and tighten it to 33-36 ft. lbs. (43-47 Nm).
  12.  
  13. Remove or disconnect the following:

    Rear O 2 S sensor electrical connector
     
    Exhaust Y-pipe
     
    Nuts that secure the front engine mounts to the front crossmember
     
    Oil pan mounting bolts
     

  14.  
  15. While supporting the oil pan, use a rubber mallet and tap the oil pan to free it from the engine.
  16.  
  17. Clean all gasket material from both mating surfaces.
  18.  

To install:

  1. Apply a continuous bead of sealer to a new oil pan gasket.
  2.  
  3. Install the oil pan assembly. Tighten the bolts to 36-48 inch lbs. (4-5 Nm).
  4.  
  5. Lower the engine onto the front crossmember.
  6.  
  7. Install or connect the following:

    Front engine mount nuts and tighten to 61 ft. lbs. (83 Nm)
     
    Y-pipe with new gaskets. Tighten the pipe-to-engine nuts to 23 ft. lbs. (30 Nm)
     
    Rear O 2 S sensor electrical connector
     
    Engine under cover
     
    Front wheel and tire assemblies
     

  8.  
  9. Remove the engine lifting device.

    Front O 2 S sensor electrical connector
     
    Pitching stopper. Tighten the front bolt to 40 ft. lbs. (54 Nm) and the rear bolt to 49 ft. lbs. (67 Nm).
     
    Upper radiator brackets
     
    Air intake duct
     
    Negative battery cable
     

  10.  
  11. Fill the engine to the proper level with the recommended oil and run the engine. Check for leaks.
  12.  

2.5L Engine


Click image to see an enlarged view

Fig. Oil pan and lubrication components-2.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle safely on jackstands.
  4.  
  5. Drain the oil from the engine into a suitable container.
  6.  
  7. Install the drain plug with a new gasket and tighten it to 33-36 ft. lbs. (43-47 Nm).
  8.  
  9. Remove the air intake duct.
  10.  
  11. Disconnect the oxygen sensor electrical connector.
  12.  
  13. Remove the pitching stopper.
  14.  
  15. Remove the upper radiator brackets.
  16.  
  17. Remove the exhaust front Y-pipe.
  18.  
  19. Remove the nuts which secure the front engine mounts to the front crossmember.
  20.  
  21. Support the engine with a suitable lifting device.
  22.  
  23. Lift up the engine slightly.
  24.  
  25. Remove the bolts that secure the oil pan.
  26.  
  27. While supporting the oil pan. use a rubber mallet and tap the oil pan to free it from the engine. Be sure to support the oil pan.
  28.  
  29. Clean all gasket material from both mating surfaces.
  30.  

To install:

  1. Apply a continuous bead of sealer to a new oil pan gasket.
  2.  
  3. Install the oil pan assembly. Tighten the bolts to 3-4 ft. lbs. (4-5 Nm).
  4.  
  5. The remainder of installation is the reverse of removal. Tighen each component to specifcations.
  6.  
  7. Fill the engine to the proper level with the recommended oil and run the engine. Check for leaks.
  8.  

DOHC Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the front tires and wheels.
  6.  
  7. Remove the collector cover.
  8.  
  9. Lower the vehicle.
  10.  
  11. Disconnect the connector from the MAF sensor.
  12.  
  13. Remove the air intake boot and air cleaner upper cover.
  14.  
  15. Remove the intercooler.
  16.  
  17. Remove the pitching stopper.
  18.  
  19. Remove the radiator upper brackets.
  20.  
  21. Properly support the engine with a lifting device and wire ropes.
  22.  
  23. Lift the vehicle and support it safely.
    NOTE
    When lifting the vehicle, raise the wire ropes at the same time.

  24.  
  25. Remove the under cover.
  26.  
  27. Drain the engine oil.
  28.  
  29. Remove the front exhaust pipe.
  30.  
  31. Remove the nuts which retain the front cushion rubber onto the front crossmember.
  32.  
  33. Remove the bolts that retain the oil pan to the cylinder block, with the engine in the raised position.
  34.  
  35. Insert an oil pan gasket cutter tool into the gap between the cylinder block and the oil pan. Remove the oil pan from the engine.
    NOTE
    Do not use a screwdriver or similar tool in place of the cutter tool.

  36.  
  37. Remove the oil strainer, if required. Remove the baffle plate, if required.
  38.  

To install:

  1. Be sure to clean the old gasket material from the mating surfaces.
  2.  
  3. Apply a continuous bead of sealer to a new oil pan gasket.
  4.  
  5. Make sure that the seals (A) are installed securely on the baffle plate and in the direction shown in the illustration. Install the baffle plate; tighten the retaining bolts to 4.7 ft. lbs.
  6.  
  7. Replace the O-ring and install the oil strainer. Tighten the bolt to 7.2 ft. lbs.
  8.  
  9. Apply liquid gasket, part number 004403012 or equivalent, to the oil pan mating surface. Install the oil pan. Torque the retaining bolts to specification.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Torque the front cushion mounting bolts to 61 ft. lbs.
  14.  
  15. Be sure to fill the engine with the correct grade and type engine oil.
  16.  
  17. Start the engine and check for leaks. Correct as required.
  18.  

SOHC Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the front tires and wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the air intake duct and the air cleaner case. Remove the air intake chamber.
  10.  
  11. Remove the pitching stopper.
  12.  
  13. Remove the hood stay holder and the radiator upper brackets.
  14.  
  15. Properly support the engine with a lifting device and wire ropes.
  16.  
  17. Lift the vehicle and support it safely.
    NOTE
    When lifting the vehicle, raise the wire ropes at the same time.

  18.  
  19. Remove the under cover.
  20.  
  21. Drain the engine oil.
  22.  
  23. Remove the front and center exhaust pipes.
  24.  
  25. Remove the nuts which retain the front cushion rubber onto the front crossmember.
  26.  
  27. Remove the bolts that retain the oil pan to the cylinder block, with the engine in the raised position.
  28.  
  29. Insert an oil pan gasket cutter tool into the gap between the cylinder block and the oil pan. Remove the oil pan from the engine.
    NOTE
    Do not use a screwdriver or similar tool in place of the cutter tool.

  30.  
  31. Remove the oil strainer, if required. Remove the baffle plate, if required.
  32.  

To install:

  1. Be sure to clean the old gasket material from the mating surfaces.
  2.  
  3. Apply a continuous bead of sealer to a new oil pan gasket.
  4.  
  5. Make sure that the seals (A) are installed securely on the baffle plate and in the direction shown in the illustration. Install the baffle plate; tighten the retaining bolts to 4.7 ft. lbs.

    Click image to see an enlarged view

    Fig. Oil pan baffle plate seal location and positioning-2005 2.5L engine

  6.  
  7. Replace the O-ring and install the oil strainer. Tighten the bolt to 7.2 ft. lbs.
  8.  
  9. Apply liquid gasket, part number 004403012 or equivalent, to the oil pan mating surface. Install the oil pan. Torque the retaining bolts to specification.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Torque the front cushion mounting bolts to 63 ft. lbs.
  14.  
  15. Be sure to fill the engine with the correct grade and type engine oil.
  16.  
  17. Start the engine and check for leaks. Correct as required.
  18.  

3.0L Engine

NOTE
If removing the upper oil pan, the engine must first be removed from the vehicle.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the under cover. Drain the engine oil.
  6.  
  7. Remove the lower oil pan retaining bolts.
  8.  
  9. Insert an oil pan gasket cutter tool into the gap between the upper oil pan and the lower oil pan. Remove the lower oil pan from the engine.
    NOTE
    Do not use a screwdriver or similar tool in place of the cutter tool.

  10.  
  11. Remove the oil strainer, if required.
  12.  

To install:

  1. Be sure to clean the old gasket material from the mating surfaces.
  2.  
  3. Replace the O-ring and install the oil strainer. Tighten the bolt to 4.7 ft. lbs.
  4.  
  5. Apply a continuous bead (0.039 inch thick) of liquid gasket, part number K0877YA018 or equivalent, to the mating surfaces. Install the oil pan. Torque the retaining bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-3.0L engine

  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Be sure to fill the engine with the correct grade and type engine oil.
  10.  
  11. Start the engine and check for leaks. Correct as required.
  12.  

3.3L Engine


Click image to see an enlarged view

Fig. Oil pan and lubrication components-3.3L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the left side O 2 sensor connector.
  6.  
  7. Remove the bolts securing the dipstick tube to the cylinder head.
  8.  
  9. Raise and safely support the vehicle on jackstands.
  10.  
  11. Drain the engi