Oil Pan

Oil Pan

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Remove the generator. For additional information, refer to Charging System Service and Repair.

3. Remove the engine cooling fan. For additional information, refer to Engine Cooling - Gasoline Engines Service and Repair.

4. Remove the Throttle Body (TB) spacer. For additional information, refer to Fuel Charging and Controls - 6.8L (3V) Service and Repair.

5. Install the Engine Support Bar, Support Hook and Engine Support Bracket.

6. Drain the engine oil.

7. Remove and discard the oil filter.

8. If equipped, remove the threaded insert and position the engine oil cooler aside.

9. Remove the nut, the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket from the engine front cover stud bolt.

10. Detach the fuel supply tube and the fuel vapor tube from the position retainer at the rear of the engine.

11. NOTICE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

NOTE: The transmission support insulator studs may come out of the insulator while removing the nuts. Install new transmission support insulator studs (part number W790019) if the studs come out of the insulator.

Remove and discard the 2 transmission support insulator-to-crossmember nuts.

12. If equipped, remove the bolts and the skidplate.

13. NOTE: Some vehicles are equipped with a catalytic converter delete pipe instead of a catalytic converter.

Remove and discard the 2 exhaust Y-pipe flange bolts and nuts.

15. NOTICE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

NOTICE: Only use hand tools when loosening the engine support insulator nuts or damage to the engine support insulator may occur.

NOTE: The engine support insulator studs may come out of the insulator while removing the nuts. Install new engine support insulator studs if the studs come out of the insulator.

Remove and discard the 4 RH engine support insulator nuts.

16. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine assembly.

17. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

18. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.

19. Disconnect the transmission wiring harness retainers and route the wiring harness over the top of the transmission and out of the way.

20. Remove the flexplate inspection cover.

1. Remove the 2 bolts.

2. Remove the inspection cover.

21. NOTICE: Support the transmission on the oil pan rails only or internal transmission damage can occur.

Install a Transmission Jack and raise the transmission.

22. Remove the 18 bolts and partially lower the oil pan.

23. Remove the 3 bolts and position the oil pump screen and pickup tube into the oil pan.

24. Remove the oil pan and the oil pump screen and pickup tube.
- Discard the oil pan gasket.

- Discard the oil pump screen and pickup tube O-ring seal.

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Failure to follow this procedure may cause future oil leakage.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

2. NOTICE: Make sure to install a new O-ring seal. A missing or damaged O-ring seal can cause foam in the lubrication system and low oil pressure. Failure to follow this instruction may result in engine damage.

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

Install a new O-ring seal onto the oil pump screen and pickup tube.

3. Position the oil pump screen and pickup tube in the oil pan and position the oil pan and new gasket into the vehicle.

4. NOTICE: Make sure to install a new O-ring seal. A missing or damaged O-ring seal can cause foam in the lubrication system and low oil pressure. Failure to follow this instruction may result in engine damage.

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

Position the oil pump screen and pickup tube and install the bolts.

- Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).

- Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

5. 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 may cause future oil leakage.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

6. 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 may cause future oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.

7. Position the oil pan gasket and the oil pan and loosely install the 18 bolts.

8. Tighten the 18 bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 20 Nm (177 lb-in).

- Stage 3: Tighten an additional 60 degrees.

9. Lower the transmission and remove the jack.

10. Install the flexplate inspection cover.

1. Position the flexplate inspection cover.

2. Install the 2 bolts.
- Tighten to 34 Nm (25 lb-ft).

11. Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.

12. NOTICE: The engine support insulator nuts can not be tightened until the support insulators are supporting the full weight of the engine and transmission assembly, or damage to the vehicle or engine support insulator may occur.

NOTE: Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign material prior lowering the engine assembly.

Using the Engine Support Bar, Support Hook and Engine Support Bracket, lower the engine into place and remove the Engine Support Bar, Support Hook and Engine Support Bracket.

13. NOTICE: The engine support insulator nuts must be discarded and new nuts installed, or damage to the vehicle or engine support insulator may occur.

NOTICE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 3 new engine support insulator-to-crossmember nuts.

- Tighten to 200 Nm (148 lb-ft).

14. NOTICE: The engine support insulator nuts must be discarded and new nuts installed, or damage to the vehicle or engine support insulator may occur.

NOTICE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

NOTE: The engine support insulator studs may come out of the insulator while removing the nuts. Install new engine support insulator studs if the studs come out of the insulator.

Install 4 new RH engine support insulator-to-crossmember nuts.

- Tighten to 115 Nm (85 lb-ft).

- If required, install new engine support insulator stud(s) (W790018) and tighten to 80 Nm (59 lb-ft).

15. Route the wiring harness over the top of the transmission and connect the wiring harness retainers.

16. Connect the CMS electrical connector.

17. Connect the TSS sensor electrical connector.

18. NOTE: Some vehicles are equipped with a catalytic converter delete pipe instead of a catalytic converter.

Install 2 new exhaust Y-pipe flange bolts and nuts.

- Tighten to 40 Nm (30 lb-ft).

19. If equipped, position the skid plate and install the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).

20. Attach the fuel supply tube and the fuel vapor tube to the position retainer at the rear of the engine.

21. NOTICE: The transmission support insulator-to-crossmember nuts must be discarded and new nuts installed, or damage to the vehicle or transmission support insulator may occur.

NOTE: The transmission support insulator studs may come out of the insulator while removing the nuts. Install new transmission support insulator studs if the studs come out of the insulator.

NOTE: Clean the transmission support insulator-to-crossmember mating surfaces of any dirt or foreign material prior to installation.

Install 2 new transmission support insulator-to-crossmember nuts.

- Tighten to 115 Nm (85 lb-ft).

- If required, install new transmission support insulator stud(s) (W790019) and tighten to 75 Nm (55 lb-ft).

22. Position the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket onto the engine front cover stud bolt and install the nut.
- Tighten to 25 Nm (18 lb-ft).

23. If equipped, position the engine oil cooler and install the threaded insert.
- Tighten to 58 Nm (43 lb-ft).

24. Install a new oil filter.
- Tighten to 16 Nm (142 lb-in).

25. Install the TB spacer. For additional information, refer to Fuel Charging and Controls - 6.8L (3V) Service and Repair.

26. Install the engine cooling fan. For additional information, refer to Engine Cooling - Gasoline Engines Service and Repair.

27. Install the generator. For additional information, refer to Charging System Service and Repair.

28. Fill the crankcase with clean engine oil.