Chrysler Full-Size Vans 1989-1998 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine oil dipstick.
  4.  
  5. Remove the air cleaner intake tube.
  6.  
  7. Unbolt the engine controller from the cowl. DO NOT DISCONNECT.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Drain the engine oil.
  12.  


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.

  1. Remove the transmission cooler lines from the oil pan mounting clips.
  2.  
  3. Remove the engine to transmission support braces.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: The engine-to-transmission braces are bolted to the engine block and the bell housing

  1. Remove the starter.
  2.  
  3. Remove the transmission inspection cover.
  4.  
  5. Support the right side of the engine.
  6.  
  7. Remove the nut on the passenger side motor mount. Loosen but do not remove the driver's side nut.
  8.  
  9. Remove the exhaust Y-pipe.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: The exhaust system's Y-pipe, which runs from the manifolds to the catalytic converter, must be removed in order to remove the oil pan

  1. Support the transmission.
  2.  
  3. Remove the transmission support insulator bolts.
  4.  
  5. Remove the oil pan bolts.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Most of the oil pan bolts are visible in this photo; others are blocked by the front crossmember

  1. Raise the engine and transmission enough to allow the oil pan to be removed.
  2.  

The engine may have to be rotated for the pan to clear the number 1 and 2 journal counterweight on removal.

To install:
  1. Thoroughly clean the gasket surfaces on the oil pan and the block.
  2.  
  3. Fabricate four dowels using 1 1 / 2 x 5 / 16 inch bolts. Cut the heads off the bolts and cut a slot into the top of each one. This will allow easier installation of the pan and gasket.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Fabricate alignment dowels from the appropriate size bolts to appear as shown

  1. Install the four dowels in the four corners of the block-to-oil pan mating surface.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Position the dowels at the 4 corners of the engine block as shown

  1. Apply a small amount of RTV sealant in the corner of the cap and the cylinder block.
  2.  



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Fig. Fig. 6: Apply RTV sealer to the indicated locations

  1. Position the gasket over the dowels and onto the engine block. Position the oil pan over the dowels and onto the block. Hand start a couple of the oil pan bolts to hold it in place.
  2.  
  3. Tighten the oil pan bolts to 200 inch lbs. (23 Nm). Remove the dowels and install the remaining bolts.
  4.  
  5. Lower the engine and transmission into place. Tighten the engine mount nuts to 75 ft. lbs. (102 Nm). Tighten the transmission support bolts to 50 ft. lbs. (68 Nm). Remove the engine and transmission supports.
  6.  
  7. Install the exhaust Y-pipe.
  8.  
  9. Install the transmission inspection cover.
  10.  
  11. Install the starter, and tighten bolts to 50 ft. lbs. (68 Nm).
  12.  
  13. Install the engine to transmission support braces.
  14.  
  15. Place the transmission oil cooler line back into its clips on the oil pan.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the upper fan shroud.
  20.  
  21. Install the engine controller.
  22.  
  23. Install the engine oil dipstick.
  24.  
  25. Install the air cleaner intake tube.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Refill the engine with oil.
  30.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Start the engine and check for leaks. Turn the engine off and check the oil level.
  2.  

 
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