Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Oil Pan

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REMOVAL & INSTALLATION




CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

Except 2.5L Premier Engine

See Figures 1 through 8

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Fig. Fig. 1: Exploded view of the lubrication system for all 2.2L and 2.5L except Premier engines



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Fig. Fig. 2: After raising the vehicle, remove the oil pan attaching bolts ...



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Fig. Fig. 3: ... then lower the oil pan from the engine block



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Fig. Fig. 4: Once the oil pan is removed, access to the oil pump can be gained



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Fig. Fig. 5: Remove the old oil pan end gaskets from the engine block



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Fig. Fig. 6: Use a scraper, if necessary, to remove the old side gaskets



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Fig. Fig. 7: Apply sealant to the ends of the new oil pan end seals at the junction of the cylinder block pan rail gasket-1988-95 2.2L and 2.5L except Premier engines



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Fig. Fig. 8: Clean the gasket mating surface of the oil pan of all old gasket material, dirt, grease or other grime-2.6L engine

  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Drain the engine oil, as described in Routine Maintenance . This would also be a good time to change the oil filter.
  4.  
  5. Remove the engine-to-transaxle struts, if so equipped. These struts prohibit access to the oil pan mounting bolts.
  6.  
  7. Remove the torque converter or clutch inspection cover.
  8.  
  9. Support the oil pan and remove the mounting bolts.
  10.  
  11. Lower the pan and remove the old gasket, if so equipped.
  12.  

To install:
  1. Clean all gasket surfaces thoroughly.
  2.  
  3. For 2.6L engines, position a new gasket on the oil pan using a sealer to hold it in place.
  4.  

1981-87 2.2 and 2.5 Liter engine uses a liquid form-in-place type gasket. Chrysler Part Number 4205918, or equivalent RTV gasket material must be used.

  1. For 1981-87 2.2 and 2.5L engines, install new end seals and apply the form-in-place gasket sealant. The RTV gasket material should be applied in a continuous bead approximately 1 / 8 in. (3mm) in diameter. All mounting holes must be circled. Uncured RTV may be removed with a rag. The oil pan should be tightened in place while the RTV is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing of the material off location. Make sure to apply sealer where the end seals meet the block.
  2.  

1988-95 2.2L and 2.5L engines utilize end seals and side gaskets, not liquid gasket as with 1981-87 models.

  1. On 1988-95 2.2L and 2.5L engines, install new end seals and side gaskets. Apply RTV sealant to the parting lines between the end and side seals on these engines. If necessary, use a little grease or RTV sealant to hold the side seals in place.
  2.  
  3. Tighten the pan bolts in a crisscross fashion, starting from the center of the oil pan and working toward the ends, to the following torque values:

    2.6L engine-53-61 inch lbs. (5.9-6.8 Nm)
     
    1981-87 2.2L and 2.5L engines-16 ft. lbs. (22 Nm)
     
    1988-95 2.2L and 2.5L engines-M8 bolts, 16 ft. lbs. (22 Nm); M6 bolt, 105 inch lbs. (12 Nm)
     

  4.  
  5. Allow the oil pan to sit for 15 minutes to ensure that the RTV sealant has completely set.
  6.  
  7. Install the oil drain plug and a new oil filter, if equipped, then lower the vehicle.
  8.  
  9. Refill the engine with oil, as described in Routine Maintenance .
  10.  
  11. Start the engine and check for oil leaks.
  12.  

2.5L Premier Engine

See Figures 9, 10 and 11

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Fig. Fig. 9: Install alignment plates so that the oil pan can be installed flush with the back edge of the engine block



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Fig. Fig. 10: The 2.5L Premier engine uses side gaskets and end oil seals to seal the oil pan to the engine block



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Fig. Fig. 11: Install the oil pan mounting bolts and studs in their correct positions, as shown

The 2.5L Premier engine is only found in the Premier models; all other 2.5L engines were manufactured by Chrysler.

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the engine oil, as described in Routine Maintenance . This would be a good opportunity to replace the old oil filter.
  6.  
  7. Disconnect the exhaust down pipe from the exhaust manifold.
  8.  
  9. Disconnect the exhaust hanger from the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter motor, as described in Engine Electrical .
  12.  
  13. Remove the torque converter/flywheel housing access cover.
  14.  
  15. Remove the oil pan bolts, then lower the oil pan from the engine.
  16.  

To install:
  1. Clean the block and oil pan surfaces to remove old gasket material and sealant.
  2.  
  3. The back of the oil pan must be flush with the back of the cylinder block. Install alignment plates to the rear of the engine block at the bottom transaxle housing mounting bolt holes.
  4.  
  5. Install a replacement seal at the bottom of the timing case cover and at the rear bearing cap.
  6.  
  7. Install side gaskets on the cylinder block mating surfaces.
  8.  
  9. Install the oil pan and bolts. Make sure to install the bolts in the correct bolt holes (as shown in the accompanying illustration). Tighten the 1 / 4 -20 bolts and studs (F and G) to 80 inch lbs. (9 Nm) and the 5 / 16 -18 bolts (D and E) to 134 inch lbs. (15 Nm).
  10.  
  11. Remove the oil pan alignment plates.
  12.  
  13. Install the torque converter/flywheel housing access cover.
  14.  
  15. Install the starter motor. For more information, refer to Engine Electrical .
  16.  
  17. Connect the exhaust down pipe to the hanger and to the exhaust manifold, as described at the end of this section.
  18.  
  19. Install the oil drain plug using a new gasket. Tighten the plug to 25 ft. lbs. (34 Nm).
  20.  
  21. Lower the vehicle and remove the wheel blocks.
  22.  
  23. Fill the engine with clean, new engine oil. For more information, refer to Routine Maintenance .
  24.  
  25. Connect the negative battery cable.
  26.  

 
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