Oil Pan: Service and Repair
Oil PanSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the intake manifold.
3. Remove the fan shroud and the engine cooling fan. For additional information, refer to Cooling System.
4. Remove the retainers and the shield.
5. Release the wiring retainers from the heater outlet tube bracket.
1 Release the knock sensor (KS) electrical connector retainer.
2 Release the engine harness routing clip retainer.
6. Disconnect the coolant hose from the heater outlet tube.
7. Remove the 2 heater outlet tube studs.
8. Remove the heater outlet tube.
^ Discard the O-ring seals.
9. Remove the 2 upper transmission-to-engine bolts.
10. Assemble the special tools.
11. Install the special tools.
12. Install the special tool and support the engine.
13. Drain the engine oil, remove and discard the oil filter.
14. NOTE: RH shown, LH similar.
Remove the 4 engine support insulator-to-crossmember nuts.
15. Remove the 2 bolts and the flexplate inspection plate.
16. Using the special tool, raise the engine 260.35 mm (10.25 inch) from the crankshaft pulley to the lower edge of the No. 1 crossmember.
17. Remove the oil pan bolts and partially lower the oil pan.
18. Remove the 3 bolts retaining the oil pump screen and pickup tube. Position the bolts and the oil pump screen and pickup tube in the oil pan.
19. Remove the oil pan from the rear of the engine.
^ Discard the oil pan gasket.
20. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
Installation
All engines
1. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply the silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
2. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in the locations shown.
3. Position the oil pump screen and pick-up tube and the 3 bolts into the oil pan and position the oil pan and new oil pan gasket onto the crossmember.
4. Position the oil pump screen and pickup tube and install the 3 bolts.
^ Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 inch lbs.).
^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 ft. lbs.).
5. Position the new oil pan gasket and the oil pan and loosely install the 16 bolts.
6. Tighten the bolts in 3 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 60 degrees.
7. Install a new oil filter.
8. Lower the engine and remove the special tools.
9. NOTE: RH shown, LH similar.
Install the 4 engine support insulator-to-crossmember nuts.
^ Tighten to 90 Nm (66 ft. lbs.).
10. Position the flexplate inspection plate and install the 2 bolts.
^ Tighten to 34 Nm (25 ft. lbs.).
11. Install the 2 upper transmission-to-engine bolts.
^ Tighten to 60 Nm (44 ft. lbs.).
12. NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.
Install the heater outlet tube.
Romeo engines (4.6L)
13. Install the 2 heater outlet tube studs.
^ Tighten to 25 Nm (18 ft. lbs.).
Windsor engine (5.4L)
14. Install the 2 heater outlet tube studs.
^ Tighten to 40 Nm (30 ft. lbs.).
All engines
15. Connect the coolant hose to the heater outlet tube.
16. Install the wiring retainers in the heater outlet tube bracket.
1 Install the KS electrical connector retainer.
2 Install the engine harness routing clip retainer.
17. Install the retainers and the shield.
18. Install the fan shroud and the engine cooling fan. For additional information, refer to Cooling System.
19. Install the intake manifold.
20. Fill the engine with clean engine oil.
21. CAUTION: The oil pump must be primed prior to starting the engine.
Start the engine and check for leaks.