Subaru Forester 1998-05

Oil Pan

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Removal & Installation





Click image to see an enlarged view

Fig. Oil pan and lubrication components

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the oil from the engine.
  4.  
  5. Remove or disconnect the following:

    Front wheels
     
    Negative battery cable
     
    Air intake duct
     
    Mass Air Flow (MAF) connector, on turbo models
     

  6.  
  7. Remove the intercooler as follows:
    1. Disconnect the Positive Crankcase Ventilation (PCV) hose from the pipe.
    2.  
    3. Remove the PCV pipe from the intercooler.
    4.  
    5. Disconnect the air by-pass valve hose.
    6.  
    7. Remove the intercooler-to-bracket bolts.
    8.  
    9. Loosen the clamps that connect the intercooler to the turbocharger and throttle body.
    10.  
    11. Disconnect the intercooler duct from the turbocharger and remove the intercooler.
    12.  

  8.  
  9. Remove or disconnect the following:

    Oxygen (O2S) sensor connectors, if necessary
     
    Pitching stopper
     
    Upper radiator brackets
     

  10.  
  11. Support the engine with a suitable lifting device and lift the engine slightly.

    Engine undercover
     
    Rear O2S sensor connector, if equipped
     
    Exhaust front Y-pipe and center pipe, on non turbo models
     
    Nuts which secure the front engine mounts to the front crossmember
     

  12.  
  13. Remove the oil pan.
  14.  
  15. Clean all gasket material from both mating surfaces.
  16.  

To install:

  1. Install the drain plug with a new gasket. Torque the bolt to 32 ft. lbs. (44 Nm).
  2.  
  3. Apply a continuous bead of sealer to a new oil pan gasket.
  4.  
  5. Install the oil pan assembly. Torque the bolts to 36-48 inch lbs. (4-5 Nm).
  6.  
  7. Lower the engine onto the front crossmember.
  8.  
  9. Install or connect the following:

    Front engine mount nuts. Torque the nuts to 51 ft. lbs. (69 Nm).
     
    Exhaust front Y-pipe with new gaskets, on non turbo models. Torque the nuts that secure the pipe to the engine to 23 ft. lbs. (30 Nm).
     
    O2S sensor connectors
     
    Engine undercover
     
    Pitching stopper. Torque the front bolt to 36 ft. lbs. (49 Nm) and the rear bolt to 42 ft. lbs. (57 Nm).
     
    Upper radiator brackets
     
    Air intake duct
     
    Intercooler, on turbo models
     
    MAF sensor connector, on turbo models
     
    Front wheels
     
    Negative battery cable
     

  10.  
  11. Refill the engine to the proper level with the recommended oil and run the engine.
  12.  
  13. Check for leaks.
  14.  



Click image to see an enlarged view

Fig. Oil pan and lubrication components

Exc. Turbocharged Engines
  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

  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.  

Turbocharged Engines
  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.  

 
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