Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Oil Pan

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Removal & Installation




NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain engine oil.
  6.  
  7. Remove or disconnect the following:

    Front engine mount bracket.
     
    Powertrain bending strut.
     
    Structural collar from oil pan to transaxle
     
    Transaxle lower dust cover.
     
    Oil filter and adaptor if vehicle is equipped with air conditioning
     
    Oil pan.
     

  8.  
  9. Clean oil pan and all gasket surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the engine lubricating components-2.0L engine

  10.  

To install:

  1. Apply Mopar®silicone rubber adhesive sealant or equivalent at the oil pump to engine block parting line.
  2.  
  3. Install or connect the following:
    WARNING
    The torque procedure for the structural collar must be followed, as damage to oil pan or collar could occur.



    New oil pan gasket to pan.
     
    Oil pan and tighten screws to 105 inch lbs. (12 Nm) in a crisscross pattern
     
    Oil filter and adaptor.
     
    Transaxle lower dust cover.
     
    Powertrain bending strut.
     
    Front engine mount and bracket
     

  4.  

Install the structural collar using the following 3 step torque sequence:

  1. Install the collar to oil pan bolts and tighten to 30 inch lbs. (3 Nm)
  2.  
  3. Install collar to transaxle bolts and tighten to 80 ft. lbs. (108 Nm)
  4.  
  5. Final torque the collar to oil pan bolts to 40 ft. lbs. (54 Nm)
  6.  
  7. Fill engine crankcase with proper oil to correct level.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle bending bracket
     
    Front engine mount and bracket
     
    Structural cover from the oil pan
     
    Transaxle inspection cover
     
    Oil filter and oil filter adapter if equipped with A/C
     
    Oil pan and discard the gasket
     

  6.  
  7. Clean the oil pan and gasket sealing surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and pump assembly-2.0L engine

  8.  

To install:

  1. Using a suitable rubber adhesive gasket sealant, apply a 1 / 8 inch (3mm) bead at the oil pump-to-engine block parting line.
  2.  
  3. Install or connect the following:

    Oil pan with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
     
    New oil filter and adapter, if removed
     
    Transaxle lower dust cover
     
    Structural cover to the oil pan
     
    Front engine mount and bracket
     
    Transaxle bending bracket
     
    Oil pan drain plug and gasket and torque the plug to 25 ft. lbs. (34 Nm).
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the engine oil. Install a new drain plug gasket.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The oil pan retainers are different lengths, so note the proper installed locations during removal.


    NOTE
    There is no gasket from the factory. It is sealed with silicone RTV.



    Negative battery cable
     
    Oil dipstick
     
    Front exhaust pipe
     
    Transaxle dust shield/bellhousing cover
     



    Oil pan retainers
     
    Oil pan
     

  8.  
  9. Clean all mating surfaces of any residual sealant.

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components-2.4L engine

  10.  

To install:


NOTE
Make sure to install the oil pan within 15 minutes of applying the sealant!

  1. Thoroughly degrease all mating surfaces
  2.  
  3. Using a suitable gasket sealant apply a 0.2 in. (4mm) bead around the perimeter groove of the pan and around each bolt hole.
  4.  
  5. Install or connect the following:

    Oil pan.
     
    Transaxle dust shield/bellhousing cover.
     
    Front exhaust pipe
     
    Oil dipstick
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
    WARNING
    After installing the oil pan, you MUST wait at least one hour before starting the engine.



    Start the vehicle, check for leaks and repair if necessary.
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oil dipstick
     
    Front exhaust pipe
     
    Bell housing cover
     
    Oil pan and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.
  8.  

To install:

  1. Install or connect the following:

    Oil pan with a new gasket and torque the bolts to 62 inch lbs. (7 Nm)
     
    Bell housing cover and torque the upper bolt to 80 inch lbs. (9 Nm) and the lower bolt to 19 ft. lbs. (26 Nm)
     
    Front exhaust pipe
     
    Oil dipstick
     
    Negative battery cable
     

  2.  
  3. Fill the engine with clean oil.

    Start the vehicle, check for leaks and repair if necessary.
     

  4.  

  1. Disconnect negative battery cable.
  2.  
  3. Raise vehicle on hoist and drain engine oil.
  4.  
  5. Remove the structural cover and torque reaction bracket.
  6.  
  7. Remove the bolts attaching oil pan.
  8.  
  9. Remove the oil pan.
  10.  
  11. Clean oil pan and all gasket surfaces.

    Click image to see an enlarged view

    Fig. Oil pan sealing-2002-04 2.4L engine



    Click image to see an enlarged view

    Fig. Oil pan gasket installation-2002-04 2.4L engine

  12.  

To install:

  1. Apply MOPAR® Engine RTV GEN II, or equivalent, at the oil pump to engine block parting line.
  2.  
  3. Install the oil pan gasket to the block.
  4.  
  5. Install the pan and tighten the screws to: 105 inch lbs. (12 Nm).
  6.  
  7. Install the structural cover and torque reaction bracket.
  8.  
  9. Lower vehicle and fill engine crankcase with proper oil to correct level.
  10.  
  11. Connect negative battery cable.
  12.  

  1. Disconnect negative battery cable.
  2.  
  3. Raise vehicle on hoist and drain engine oil.
  4.  
  5. Remove the structural cover.
  6.  
  7. Remove the air conditioning compressor bracket to oil pan bolt.
    NOTE
    The oil pan is sealed with RTV and may need to be pried apart.

  8.  
  9. Remove the bolts attaching oil pan.
    NOTE
    Prior to removing the oil pan, score RTV with a razor blade between the oil pan and the bed plate.

  10.  
  11. Insert pry bar at locations shown and gently pry oil pan away from the engine.

    Click image to see an enlarged view

    Fig. Right side oil pan pry point-2005 2.4L engine



    Click image to see an enlarged view

    Fig. Left side oil pan pry point-2005 2.4L engine

  12.  

To install:

Click image to see an enlarged view

Fig. RTV application for the 2005 2.4L engine oil pan


NOTE
You must assemble oil pan to bed plate before RTV -skins over-. If RTV skins before assembly, parts must be cleaned and a new bead of RTV applied.

  1. Clean oil pan and block surfaces. Clean cured RTV from oil pan and bed plate with a plastic or brass scraper.
  2.  
  3. Clean all sealing surfaces with MOPAR® Brake Parts Cleaner, or equivalent.
  4.  
  5. Inspect surfaces for damage, replace as needed.
  6.  
  7. Apply a 3-4mm diameter bead of MOPAR® Engine RTV, or equivalent, around the perimeter of the oil pan flange, 1mm away from the chamfer on the inner edge of the oil pan.
  8.  
  9. Position oil pan on bedplate.
  10.  
  11. Install the oil pan attaching bolts and tighten to 105 inch lbs. (12 Nm).
  12.  
  13. Install the air conditioning compressor bracket to oil pan bolt.
  14.  
  15. Install the structural cover.
  16.  
  17. Lower vehicle and fill engine crankcase with proper oil to correct level.
  18.  
  19. Connect negative battery cable.
  20.  
  21. Start engine and check for leaks.
  22.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the structural cover.
  10.  
  11. Remove the Air Conditioning (A/C) compressor bracket to oil pan bolt.
    NOTE
    The oil pan is sealed with RTV and may need to be pried apart.

  12.  
  13. Remove the bolts attaching the oil pan.
    NOTE
    Prior to removing the oil pan, score RTV with a razor blade between the oil pan and the bed plate.

  14.  
  15. Insert pry bar at locations shown and gently pry oil pan away from the engine.

    Click image to see an enlarged view

    Fig. Right side oil pan pry point-2.4L engine



    Click image to see an enlarged view

    Fig. Left side oil pan pry point-2.4L engine

  16.  

To install:

Click image to see an enlarged view

Fig. RTV application to the oil pan-2.4L engine


NOTE
You must assemble the oil pan to the bed plate before the RTV skins over. If RTV skins before assembly, parts must be cleaned and a new bead of RTV applied.

  1. Clean oil pan and block surfaces. Clean cured RTV from oil pan and bed plate with a plastic or brass scraper.
  2.  
  3. Clean all sealing surfaces with MOPAR® Brake Parts Cleaner, or equivalent.
  4.  
  5. Inspect surfaces for damage, replace as needed.
  6.  
  7. Apply 1 / 8 inch (3-4mm) diameter bead of MOPAR® Engine RTV, or equivalent, around the perimeter of the oil pan flange, right up to the chamfer on the inner edge of the oil pan.
  8.  
  9. Position oil pan on bedplate.
  10.  
  11. Install the oil pan attaching bolts and tighten to 105 inch lbs. (12 Nm).
  12.  
  13. Install the air conditioning compressor bracket to oil pan bolt.
  14.  
  15. Install the structural cover.
  16.  
  17. Lower the vehicle and fill the engine crankcase with the proper oil to the correct level.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and check for leaks.
  22.  

2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable and lower the front exhaust pipe
     
    Center-member
     
    Engine oil dipstick tube and dipstick
     
    Starter motor
     
    Front and rear plates
     
    Transaxle inspection cover
     
    Oil pan attaching bolts
     
    Oil pan
     

  6.  

To install:

  1. Thoroughly clean and dry the oil pan, cylinder block and cylinder block bolts and bolt holes.
  2.  
  3. Apply a continuous 3 / 16 inch (4mm) bead of silicone adhesive sealant to the oil pan gasket surface. Be sure to circle all mounting bolt holes as well. Install the oil pan within a 10-15 minute period of applying the gasket material to ensure proper sealing.

    Click image to see an enlarged view

    Fig. To ensure a leak-free seal, apply sealer as shown and tighten the bolts following the specified sequence-2.5L engine

  4.  
  5. Install or connect the following:

    Oil pan and torque the bolts to 53 inch lbs. (6 Nm)
     
    Transaxle inspection cover
     
    Front and rear plates and torque the bolts to 80 ft. lbs. (108 Nm)
     
    Starter motor
     
    Engine oil dipstick tube and dipstick
     
    Center-member and torque the bolts to 65 ft. lbs. (88 Nm)
     
    Front exhaust pipe
     
    Oil pan drain plug and gasket and torque the drain plug to 29 ft. lbs. (40 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil and install a new oil filter.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module as follows:

    Negative battery cable
     
    Exhaust cross under pipe
     
    Drive belt splash shield
     
    Oil dipstick tube
     
    Starter
     
    Engine to transaxle bending braces
     
    Transaxle inspection cover
     
    Oil pan and discard the gasket
     

  6.  
  7. Clean all mating surfaces of any residual gasket material.

    Click image to see an enlarged view

    Fig. Apply sealer to the oil pan as shown-2.5L engine

  8.  

To install:

  1. Install or connect the following:

    Oil pan with a new gasket and torque the bolts to 50 inch lbs. (6 Nm)
     
    Transaxle inspection cover
     
    Engine to transaxle bending braces
     
    Exhaust cross under pipe
     
    Starter
     
    Drive belt splash shield
     
    Oil dipstick tube
     
    Negative battery cable
     

  2.  
  3. Fill the engine with clean oil.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine support module as follows:

    Negative battery cable
     
    Oil dipstick and tube
     
    Structural cover
     
    Exhaust cross under pipe
     
    Torque converter cover
     
    Lower bolt from the A/C compressor
     
    Oil pan and discard the gasket

    Click image to see an enlarged view

    Fig. Oil pan installation-2.7L engine

     

  6.  

To install:

  1. Clean all mating surfaces of any residual gasket material.

    Oil pan with a new gasket
     

  2.  
  3. Torque the oil pan bolts as follows:
    1. Timing chain cover to oil pan bolts and torque them to 105 inch lbs. (12 Nm).
    2.  
    3. Oil pan bolts to 21 ft. lbs. (28 Nm).
    4.  
    5. Oil pan nuts to 105 inch lbs. (12 Nm).
    6.  
    7. A/C compressor bolt to 21 ft. lbs. (28 Nm).

      Torque converter cover
       
      Exhaust cross under pipe
       
      Structural cover
       
      Oil dipstick and tube
       
      Negative battery cable
       

    8.  

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine oil dipstick and tube.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the engine oil and remove the oil filter.
  10.  
  11. Remove the structural collar.
  12.  
  13. Remove the exhaust cross-under pipe.
  14.  
  15. Remove the torque converter housing cover.
  16.  
  17. Remove the lower bolt attaching the A/C compressor to the oil pan.
    WARNING
    Be sure to remove the 2 bolts attaching the timing cover to the oil pan, as damage to the timing cover and/or oil pan may occur.

  18.  
  19. Remove the oil pan attaching fasteners.
  20.  
  21. Remove the oil pan and gasket.
  22.  

To install:

Click image to see an enlarged view

Fig. Oil pan installation-2.7L engine

  1. Clean the oil pan and sealing surfaces.
  2.  
  3. Inspect the oil pan and timing chain cover gaskets. Replace as necessary.
  4.  
  5. Apply a 1 / 8 inch bead of MOPAR® Engine RTV GEN II to the front T-joints (oil pan gasket to timing cover gasket interface) and the rear T-joints (oil pan gasket to crankshaft rear oil seal retainer gasket interface).
  6.  
  7. Install the oil pan gasket to the block.
    NOTE
    To prevent oil leaks at oil pan to timing chain cover, the following tightening sequence procedure must be performed.

  8.  
  9. Install the oil pan and fasteners using the following tightening sequence:
    1. Install the oil pan bolts and nuts finger tight only-just tight enough to compress the gasket's rubber seal.
    2.  
    3. Install the timing chain cover to pan bolts. Tighten to 106 inch lbs. (12 Nm).
    4.  
    5. Tighten the oil pan bolts to 21 ft. lbs. (28 Nm).
    6.  
    7. Tighten the oil pan nuts to 106 inch lbs. (12 Nm).
    8.  

  10.  
  11. Install the lower bolt attaching the A/C compressor to the oil pan. Tighten bolt to 21 ft. lbs. (28 Nm).
  12.  
  13. Install the torque converter housing cover.
  14.  
  15. Install the oil filter and drain plug.
  16.  
  17. Install the exhaust cross-under pipe.
  18.  
  19. Install the structural collar.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the engine oil dipstick and tube.
  24.  
  25. Fill the engine crankcase with the proper oil to the correct level.
  26.  
  27. Connect the negative battery cable.
  28.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the engine support module as follows:
    WARNING
    Do not pry the lower oil pan from the engine. Tap on the side with a mallet.


    NOTE
    There is no gasket from the factory. It is sealed with silicone RTV.



    Negative battery cable
     
    Front exhaust pipe
     
    Lower oil pan and discard the gasket
     



    Starter electrical connectors
     
    Starter
     
    Oil dipstick and guide
     
    Cover
     
    Upper oil pan
     

  8.  
  9. Clean all mating surfaces of any residual gasket material.
  10.  

To install:

Click image to see an enlarged view

Fig. Tighten the upper oil pan bolts in sequence-3.0L engine



Click image to see an enlarged view

Fig. Tighten the lower oil pan bolts in sequence-3.0L engine

  1. Install or connect the following:

    Thoroughly degrease all mating surfaces
     
    Upper oil pan. Run a 0.2 in. (4mm) bead of suitable sealant around the perimeter groove of the pan and around each bolt hole. Torque the bolts, in sequence, to 53 inch lbs. (6 Nm).
     
    Cover and torque the bolts to 96 inch lbs. (11 Nm)
     
    Starter
     
    Starter electrical connectors
     
    Oil dipstick and guide with a new O-ring and torque the bolt to 36 ft. lbs. (48 Nm)
     
    Lower oil pan with fresh sealant and torque the bolts to 96 inch lbs. (11 Nm)
     
    Front exhaust pipe
     
    Negative battery cable
     

  2.  
  3. Fill the engine with clean oil.

    Start the vehicle, check for leaks and repair if necessary.
     

  4.  

 
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