Oil Pan: Service and Repair

Oil Pan





Special Tool(s)





Material

Removal
1. Remove the intake manifold.
2. Remove the fan shroud and the engine cooling fan.





3. Remove the retainers and the shield.





4. Remove the nut and position the transmission fluid filler tube aside.





5. Release the wiring retainers from the heater outlet tube bracket.
1. Release the knock sensor electrical connector retainer.
2. Release the engine harness routing clip retainer.





6. Disconnect the hose from the heater outlet tube.





7. Remove the heater outlet tube studs.





8. Remove the heater outlet tube.





9. Remove the two transmission-to-engine bolts.





10. Assemble the special tools.





11. Install the special tools.





12. Install the special tool and support the engine.
13. Raise and support the vehicle.
14. Drain the engine oil, and remove the oil filter.





15. NOTE: RH is shown; LH is similar.

Remove the four engine mount nuts.





16. Remove the flexplate inspection plate.
17. Lower the vehicle.
18. Using the Heavy Duty Engine Support, raise the engine 10-1/4 inches from the crankshaft pulley to the lower edge of the No. 1 crossmember.
19. Raise the vehicle.





20. Remove the bolts and partially lower the oil pan.





21. NOTE: Oil pan is removed for clarity.

Remove the bolts retaining the oil pump screen cover and pickup tube and let the bolts drop into the oil pan.
22. Remove the oil pan at the rear of the engine.
23. Clean the oil pan thoroughly and inspect the oil pan gasket.
24. Clean the mating surfaces for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Installation

All engines





1. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.

Install the oil pump screen and pickup tube.





2. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.





3. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.





4. Tighten the bolts in three stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 90 degrees.





5. Install a new oil filter.
6. Lower the vehicle.
7. Lower the engine and remove the special tools.
8. Raise the vehicle.





9. NOTE: RH is shown; LH is similar.

Install the four engine mount nuts.





10. Install the flexplate inspection plate.
11. Lower the vehicle.





12. Install the transmission-to-engine bolts.





13. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.

Insert the heater outlet tube over the new seals.

Romeo engines (4.6L)





14. Install the heater outlet tube studs.





15. Position the transmission fluid filler tube and install the nut.

Windsor engine (5.4L)





16. Install the heater outlet tube studs.





17. Position the transmission fluid filler tube and install the nut.

All engines





18. Connect the hose to the heater outlet tube.





19. Install the wiring retainers in the heater outlet tube bracket.
1. Install the knock sensor electrical connector retainer.
2. Install the engine harness routing clip retainer.





20. Install the retainers and the shield.
21. Install the fan shroud and the engine cooling fan.
22. Install the intake manifold.

23. CAUTION: The oil pump must be primed prior to starting the engine.

Fill the engine with clean engine oil.
24. Start the engine and check for leaks.