Cherokee, Grand Cherokee, 1999-2005

Oil Pan

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Removal & Installation



2.5L & 4.0L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Starter motor
     
    Bell housing access cover
     
    Oil level sensor connector, if equipped
     
    Left and right motor mounts
     
    Transmission oil cooler lines, if equipped
     

  6.  
  7. Place a jack under the crankshaft damper and raise the engine for clearance.
  8.  
  9. Remove the oil pan.
  10.  

To install:

  1. Fabricate 4 alignment dowels from 1 1 / 2 in. x 1 / 4 in. bolts. Cut the heads off the bolts and cut a slot into the top of the dowel to allow installation/removal with a screwdriver.

    Click image to see an enlarged view

    Fig. Fabrication of alignment dowels-4.0L engine



    Click image to see an enlarged view

    Fig. Oil pan alignment dowel placement-2.5L and 4.0L engines

  2.  
  3. Install or connect the following:

    Dowels
     
    RTV sealer at the points shown

    Click image to see an enlarged view

    Fig. RTV sealer application points-4.0L engine

     
    Oil pan, using a new gasket. Torque the 1 / 4 inch bolts to 85 inch lbs. (9.5 Nm) and the 5 / 16 inch bolts to 11 ft. lbs. (15 Nm).
     

  4.  
  5. Replace the alignment dowels with 1 / 4 inch bolts and torque them to 85 inch lbs. (9.5 Nm).
  6.  
  7. Install or connect the following:

    Left and right motor mounts
     
    Oil level sensor connector, if equipped
     
    Bell housing access cover
     
    Starter motor
     
    Exhaust front pipe
     
    Negative battery cable
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

3.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove the radiator fan.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Install engine lifting Tool 8534, or equivalent.
    NOTE
    Do not raise engine at this time.

  10.  
  11. Remove the structural cover using sequence shown.

    Click image to see an enlarged view

    Fig. Structural cover removal and installation sequence-3.7L and 4.7L engines

  12.  
  13. Remove both left and right side engine mount through bolts.
  14.  
  15. Raise engine to provide clearance to remove oil pan.
  16.  
  17. Drain engine oil and remove oil filter.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan.

  18.  
  19. Remove the oil pan mounting bolts and oil pan.
  20.  
  21. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine.
  22.  

To install:

  1. Clean the oil pan gasket mating surface of the bedplate and oil pan.
  2.  
  3. Inspect integrated oil pan gasket, and replace as necessary.
  4.  
  5. Position the integrated oil pan gasket/windage tray assembly.
  6.  
  7. Install the oil pickup tube
  8.  
  9. If removed, install stud at position No. 9.
  10.  
  11. Install the mounting bolt and nuts. Tighten nuts to 20 ft. lbs. (28 Nm).
  12.  
  13. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown.
  14.  
  15. Install structural dust cover
  16.  
  17. Lower the engine into mounts.
  18.  
  19. Remove the lifting tool.
  20.  
  21. Install both the left and right side engine mount through bolts. Tighten the nuts to 50 ft. lbs. (68 Nm).
  22.  
  23. Install the intake manifold.
  24.  
  25. Fill engine oil.
  26.  
  27. Reconnect the negative battery cable.
  28.  
  29. Start engine and check for leaks.
  30.  

4.7L Engine
  1. Disconnect negative cable from battery.
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Remove structural cover.
  6.  
  7. Remove exhaust system Y-pipe.
  8.  
  9. Remove starter.
  10.  
  11. Drain engine oil.
  12.  
  13. Un-clip transmission lines from support on oil pan stud. Move lines for oil pan clearance.
    CAUTION
    DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when lowering oil pan. Gasket can not be removed with oil pan.

  14.  
  15. Remove oil pan bolts and oil pan.
  16.  
  17. Remove oil pump pickup tube.
  18.  
  19. Remove oil pan gasket.
  20.  

To install:

Click image to see an enlarged view

Fig. Oil pan bolt tightening sequence for the 4.7L engine

  1. Clean oil pan and all sealing surfaces. Inspect oil pan gasket and replace as necessary.
  2.  
  3. Install oil pan gasket.
    NOTE
    When installing oil pan gasket/windage tray, start four pan bolts at each corner before tightening oil pickup tube. This will keep pan gasket in alignment.

  4.  
  5. Install oil pump pick-up tube using a new O-ring. First tighten bolt at O-ring end of tube to 20 ft. lbs. (28 Nm). Tighten remain tube support fasteners to 20 ft. lbs. (28 Nm).
  6.  
  7. Install oil pan and tighten fasteners to 11 ft. lbs. (15 Nm).
  8.  
  9. Reconnect transmission oil cooler lines to oil pan stud bolt.
  10.  
  11. Install starter.
  12.  
  13. Install exhaust system Y-pipe.
  14.  
  15. Install structural cover.
  16.  
  17. Lower vehicle.
  18.  
  19. Fill engine with proper amount of oil.
  20.  
  21. Connect negative cable to battery.
  22.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Structural cover
     
    Exhaust Y-pipe
     
    Starter motor
     
    Transmission oil cooler lines
     
    Oil pan
     
    Oil pump pickup tube
     
    Oil pan gasket
     

  6.  

To install:

Click image to see an enlarged view

Fig. Oil pan mounting bolt tightening sequence-4.7L engine

  1. Install or connect the following:

    Oil pan gasket
     
    Oil pump pickup tube, using a new O-ring. Torque the tube bolts to 20 ft. lbs. (28 Nm); torque the O-ring end bolt first.
     
    Oil pan. Torque the bolts, in sequence, to 11 ft. lbs. (15 Nm).
     
    Transmission oil cooler lines
     
    Starter motor
     
    Exhaust Y-pipe
     
    Structural cover
     
    Negative battery cable
     

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

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Install engine support fixture special tool 8534, or equivalent.
    NOTE
    Do not raise engine at this time.

  6.  
  7. Loosen both left and right side engine mount through bolts. Do not remove bolts.
  8.  
  9. Remove the structural dust cover.
  10.  
  11. Drain engine oil.
    WARNING
    Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.

  12.  
  13. Raise engine using special tool 8534 to provide clearance to remove oil pan.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.

  14.  
  15. Remove the oil pan mounting bolts and oil pan.
  16.  
  17. Unbolt oil pump pickup tube and remove tube.
  18.  
  19. Inspect the integral windage tray and gasket and replace as needed.
  20.  

To install:

  1. Clean the oil pan gasket mating surface of the bedplate and oil pan.
  2.  
  3. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 20 ft. lbs. (28 Nm).
  4.  
  5. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown.
  6.  
  7. Lower the engine into mounts using special tool 8534.
  8.  
  9. Install both the left and right side engine mount through bolts. Tighten the nuts to 50 ft. lbs. (68 Nm).
  10.  
  11. Remove special tool 8534.
  12.  
  13. Install structural dust cover.
  14.  
  15. Fill engine oil.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Start engine and check for leaks.
  20.  

5.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Raise vehicle.
  10.  
  11. Remove both left and right side engine mount to frame bolts.
  12.  
  13. Drain engine oil and remove the oil filter.
  14.  
  15. Remove the engine oil dipstick and tube from the oil pan.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install engine support fixture special tool 8534, or equivalent.
    NOTE
    Do not use the third leg.

  20.  
  21. Raise engine using special tool 8534 to provide clearance to remove oil pan.
  22.  
  23. Raise the vehicle.
  24.  
  25. Remove the front axle.
  26.  
  27. Remove the structural dust cover.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan.


    NOTE
    The horizontal M10 fasteners are 5mm longer in length, and must be reinstalled in original locations.

  28.  
  29. Remove the M10 fasteners (vertical and horizontal) from the rear of the oil pan to the transmission and engine.
  30.  
  31. Remove the oil pan mounting bolts using the sequence provided, and oil pan.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  32.  
  33. Discard the integral windage tray and gasket and replace.
  34.  

To install:

  1. Clean the oil pan gasket mating surface of the block and oil pan.
    NOTE
    Mopar® Engine RTV, or equivalent, must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5mm x 25mm in each of the 4 T-joint locations.



    Click image to see an enlarged view

    Fig. Mopar® Engine RTV, or equivalent, must be applied to the 4 T-joints-5.7L engine

  2.  
  3. Apply Mopar® T Engine RTV at the 4 T- joints.
    NOTE
    When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused.

  4.  
  5. Install a new oil pan gasket/windage tray assembly.
  6.  
  7. If removed, reinstall the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 250 inch lbs. (28 Nm).
    NOTE
    The horizontal M10 fasteners are 5mm longer in length, and must be reinstalled in original locations.


    NOTE
    The horizontal M10 fasteners are 5mm longer in length, and must be reinstalled in original locations.

  8.  
  9. Align the rear of the oil pan with the rear face of the engine block, and install the M10 and M6 oil pan fasteners finger tight. Using the following torque sequence, torque the M6 mounting bolts to 44 inch lbs. (5 nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-5.7L engine

  10.  
  11. Using the following torque sequence, torque the M10 oil pan fasteners to 39 ft. lbs. (54 Nm).
  12.  
  13. Using the following torque sequence, torque the M6 oil pan fasteners to 106 inch lbs. (12 Nm).
  14.  
  15. Install both the left and right side oil pan to transmission bolts. Torque the bolts to 39 ft. lbs. (54 Nm).
  16.  
  17. Lower the engine into mounts.
  18.  
  19. Install both the left and right side engine mount bolts and nuts. Torque the studs and nuts to 39 ft. lbs. (54 Nm).
  20.  
  21. Install the engine oil dipstick and tube.
  22.  
  23. Remove special tool 8534.
  24.  
  25. Install the intake manifold.
  26.  
  27. Install the front axle.
  28.  
  29. Install the engine cover.
  30.  
  31. Fill engine oil.
  32.  
  33. Install oil filter, if removed.
  34.  
  35. Reconnect the negative battery cable.
  36.  
  37. Start engine and check for leaks.
  38.  

 
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