Engine Oil Pan - Installation

AWD






CAUTION: Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar(R) Threebond Engine RTV Sealant may result in engine fluid leakage.

CAUTION: Following the application of Mopar(R) Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

1. Clean the oil pan, timing chain cover, rear seal retainer and engine block mating surfaces with isopropyl alcohol in preparation for sealant application.
2. Apply a 2 to 3 mm wide bead of Mopar(R) Threebond Engine RTV Sealant to the oil pan as shown in the following locations:
- Oil pan to engine block flange (1)
- Two timing cover to engine block T-joints (2)
- Two rear seal retainer to engine block T-joints (3)





CAUTION: Make sure that the rear face of the oil pan is flush to the transmission bell housing before tightening any of the oil pan mounting bolts. A gap between the oil pan and the transmission could crack the oil pan or transmission casting.

3. Install the oil pan to the engine block making sure the oil pan is flush to the transmission bell housing. Secure the oil pan to the engine block with nineteen M8 oil pan mounting bolts (1) finger tight.





4. Install the four transmission to the engine oil pan bolts (1) and tighten to 55 Nm (41 ft. lbs.).





5. Tighten the nineteen previously installed M8 oil pan mounting bolts (1) to 25 Nm (18 ft. lbs.).






NOTE: Shown with transmission removed for clarity.

6. Install the two M6 bolts (1) to the rear oil seal retainer flange and tighten to 12 Nm (9 ft. lbs.).





7. Install the two rubber plugs (1) covering the rear oil seal retainer flange bolts.





8. Lower the rear of the engine and install the two bolts (2) to the rear engine mount isolator. Tighten the bolts to 65 Nm (48 ft. lbs.).





9. Install the transmission cooling lines (2) and tighten the bolt (1) to 12 Nm (106 in. lbs.).





10. Lift the steering gear (1) into the mounted position and install the steering gear lower mounting bolts (2 and 3). Install the upper mounting bolt (4) and nut. Tighten all bolts to 102 Nm (75 ft. lbs.).




Align splines and install the lower intermediate shaft coupling (2) to the steering gear shaft (3). Install a NEW pinch bolt and tighten to 45 Nm (33 ft. lbs.).





11. Raise the stabilizer bar to the engine cradle, placing bushings (1) into the mounted position.
12. Install the bolts (2) securing each stabilizer bar isolator retainer (3) to the cradle. Tighten the bolts to 60 Nm (44 ft. lbs.).





13. Install the front axle assembly (1) with propeller shaft, intermediate shaft, halfshafts, wheels, tires and exhaust pipe Installation.
14. If required, fill the front axle with the specified type and amount of gear lubricant.





15. Position the belly pan and install the retainers (1).
16. Lower the vehicle.





17. Install the oil level indicator (2) with bolt (1) tightened to 12 Nm (106 in. lbs.).
18. Position the heater core inlet tube (4) and install two bolts (3) tightened to 12 Nm (106 in. lbs.).
19. Fill the crankcase with the specified type and amount of engine oil .





20. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
21. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
22. Tighten the clamp at the air cleaner housing (3) to 5 Nm (44 in. lbs.).
23. Tighten the clamp (2) at the throttle body to 5 Nm (44 in. lbs.).
24. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).





25. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
26. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
27. Start and run the engine until it reaches normal operating temperature and check for leaks.