Oil Pan

REMOVAL & INSTALLATION

2.3L and 2.5L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   • Negative battery cable
   • Engine from the vehicle and place it on a suitable engine stand
   • Oil pan and discard the gasket

   To install:

   Fig. 1: Tighten the oil pan bolts in sequence 2.3L–2.5L engines

4. Clean the mating surface on the oil pan.
5. Install or connect the following:
   • Oil pan gasket
   • Apply a bead of silicone sealant to the oil pan
   • Oil pan. Torque the bolts in sequence to 141 inch lbs. (16 Nm).
   • Engine
   • Negative battery cable
6. Fill the engine with clean oil.
7. Start the vehicle and check for leaks, repair if necessary.

3.0L Engine

2WD

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   • Negative battery cable
   • Oil level dipstick tube
   • Fan shroud. Leave the fan shroud over the fan assembly
   • Motor mount nuts from the frame

   WARNING
   On models equipped with distributor ignition, failure to remove the distributor will damage or break it when the engine is lifted.

   • Starter
   • Transmission inspection cover
   • Right hand axle I-beam. The brake caliper must be removed and secured out of the way.
   • Oil pan attaching bolts, using a suitable lifting device, raise the engine about 2 in. (5cm)
   • Oil pan and discard the gasket

   NOTE: The oil pan fits tightly between the transmission spacer plate and oil pump pick-up tube. Use care when removing the oil pan from the engine.

4. Clean all gasket surfaces on the engine and oil pan. Remove all traces of old gasket and/or sealer.

   To install:

5. Apply a ¹⁄₈ (4mm) bead of RTV sealer to the junctions of the rear main bearing cap and block, and the front cover and block. The sealer sets in 15 minutes, so work quickly!
6. Apply adhesive to the gasket surfaces and install the oil pan gasket.
7. Install or connect the following:
   • Oil pan on the engine block. Torque the bolts EVENLY to 9 ft. lbs. (12 Nm) working from the center to the end position on the oil pan.
   • Right hand axle I-beam
   • Brake caliper
   • Transmission inspection cover
   • Starter
   • Fan shroud
   • Motor mount retaining nuts
   • Oil level dipstick tube
   • Negative battery cable
8. Fill the engine with clean oil.
9. Start the vehicle and check for leaks, repair if necessary.

4WD

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   • Negative battery cable
   • Engine from the vehicle and place it on a suitable engine stand
   • Oil pan and discard the gasket

   To install:

4. Install or connect the following:
   • New oil pan gasket and secure the gasket with trim adhesive
   • Oil pan. Torque the bolts to 9 ft. lbs. (12 Nm).
   • Engine
   • Negative battery cable
5. Fill the engine with clean oil.
6. Start the vehicle and check for leaks, repair if necessary.

4.0L OHV Engine

NOTE: Review the complete service procedure before starting this repair.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   • Negative battery cable
   • Engine from the vehicle and mount the engine on a suitable engine stand with the oil pan facing up
   • Oil pan attaching bolts (note location of 2 spacers) and remove the pan from the engine block
   • Oil pan gasket and crankshaft rear main bearing cap wedge seal
4. Clean all gasket surfaces on the engine and oil pan. Remove all traces of old gasket and/or sealer.

   To install:

5. Install or connect the following:
   • New crankshaft rear main bearing cap wedge seal. The seal should fit snugly into the sides of the rear main bearing cap

     Fig. 2: The correct spacer must be used to extend the mounting surface of the oil pan so it is flush with the mounting surface of the engine block–4.0L OHV engine

   • New oil pan gasket to the engine block and place the oil pan in correct position on the 4 locating studs. Torque the bolts EVENLY to 60–84 inch lbs. (7–10 Nm).
   • Transmission bolts to the engine and oil pan. There are 2 spacers on the rear of the oil pan to allow proper mating of the transmission and oil pan.
   • Spacers to the mounting pads on the rear of the oil pan before bolting the engine and transmission together
   • Engine to the vehicle
   • Negative battery cable
6. Fill the engine with clean oil.
7. Start the vehicle and check for leaks, repair if necessary.