Upper Oil Pan Replacement

Upper Oil Pan Replacement

Special Tools

J 37228 Seal Cutter

Removal Procedure




1. Remove the oil level indicator.
2. Remove the oil level indicator tube bolt from the indicator tube bracket.
3. If vehicle is a 4-wheel drive (4WD), remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (Service and Repair).
4. If vehicle is a 2-wheel drive (2WD), disconnect the relay rod from the pitman arm and idler arm. Refer to Relay Rod Replacement (Service and Repair).
5. Remove the lower oil pan. Refer to Lower Oil Pan Replacement (Lower Oil Pan Replacement).
6. Remove the engine flywheel. Refer to Engine Flywheel Replacement (Engine Flywheel Replacement).




7. Remove the battery cable bracket bolts.




8. Remove the battery cable bracket nut.




9. Remove the two flywheel housing to upper oil pan bolts.




10. Remove the upper oil pan bolts and any brackets. Mark the bolt location of the bracket.
11. Separate the upper oil pan from the engine block using J 37228 .
12. Remove the upper oil pan. The oil level indicator tube needs to be removed while lowering the upper oil pan.
13. If required, clean and inspect the upper oil pan. Refer to Upper Oil Pan Cleaning and Inspection (81. Upper Oil Pan Cleaning and Inspection).

Installation Procedure




1. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the upper oil pan mating surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
2. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the flywheel housing sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.




3. Install the upper oil pan to the engine block. Ensure the oil level indicator tube is installed into the upper oil pan.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install any brackets and the upper oil pan bolts in the sequence shown.

Tighten the bolts to 20 Nm (15 lb ft).




5. Install the two flywheel housing to upper oil pan bolts.

Tighten the bolts to 50 Nm (37 lb ft).




6. Install the battery cable bracket bolts.

Tighten the bolts to 12 Nm (106 lb in).




7. Install the battery cable bracket nut.

Tighten the nut to 8 Nm (71 lb in).




8. Install the engine flywheel. Refer to Engine Flywheel Replacement (Engine Flywheel Replacement).
9. Install the lower oil pan. Refer to Lower Oil Pan Replacement (Lower Oil Pan Replacement).
10. If vehicle is a 4WD, install the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (Service and Repair).
11. If vehicle is a 2WD, Connect the relay rod to the pitman arm and idler arm. Refer to Relay Rod Replacement (Service and Repair).
12. Lower the vehicle.
13. Install the oil level indicator tube bolt to the indicator tube bracket.

Tighten the bolt to 21 Nm (15 lb ft).

14. Install the oil level indicator.
15. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).