Dakota, 2001-2005

Oil Pan

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Removal & Installation



2.5L 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
     

  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 inch x 1 / 4 inch bolts. Cut the heads off the bolts and cut a slot into the top of the dowel to allow installation/removal with a screwdriver.
  2.  
  3. Install or connect the following:

    Dowels
     
    Oil pan, using a new gasket. Tighten 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 tighten 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 crankcase.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Install an engine support fixture. 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, if equipped.
  10.  
  11. Drain engine oil.
  12.  
  13. Remove the front crossmember.
    NOTE
    Raise the engine just enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold.

  14.  
  15. Raise engine 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.

  16.  
  17. Remove the oil pan mounting bolts and oil pan.
  18.  
  19. Unbolt oil pump pickup tube and remove tube.
  20.  
  21. Inspect the integral windage tray and gasket and replace as needed.
  22.  

To install:

Click image to see an enlarged view

Fig. Oil pan bolt torque sequence-3.7L Engine



Click image to see an enlarged view

Fig. 3.7L engine bedplate bolt torque sequence

  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 28 Nm (20 ft. lbs.).
  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. Lower the engine into mounts.
  16.  
  17. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 Nm (50 ft. lbs.).
  18.  
  19. Remove the lifting device.
  20.  
  21. Install structural dust cover, if equipped.
  22.  
  23. Install the front crossmember.
  24.  
  25. Fill engine oil.
  26.  
  27. Reconnect the negative battery cable.
  28.  
  29. Start engine and check for leaks.
  30.  

3.9L Engine
2-Wheel Drive
  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
     
    Distributor cap
     
    Oil dipstick
     
    Exhaust front pipe
     
    Flywheel access panel, if equipped
     
    Left and right motor mount through bolts
     
    Oil pan. Raise the engine as necessary for clearance.

    Click image to see an enlarged view

    Fig. Oil pan alignment dowel placement-3.9L engine shown

     

  6.  

To install:

  1. Fabricate 4 alignment dowels from 1 1 / 2 inch x 1 / 4 inch bolts. Cut the heads off the bolts and cut a slot into the top of the dowel to allow installation/removal with a screwdriver.
  2.  
  3. Install or connect the following:

    Alignment dowels
     
    Oil pan. Replace the dowels with bolts and tighten all bolts to 17 ft. lbs. (23 Nm).
     
    Left and right motor mount through bolts
     
    Flywheel access panel, if equipped
     
    Exhaust front pipe
     
    Oil dipstick
     
    Distributor cap
     
    Negative battery cable
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

4-Wheel Drive
  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
     
    Engine oil dipstick
     
    Front axle. Support the engine
     
    Exhaust front pipe
     
    Flywheel access panel, if equipped
     
    Oil pan
     

  6.  

To install:

  1. Fabricate 4 alignment dowels from 1 1 / 2 inch x 1 / 4 inch bolts. Cut the heads off the bolts and cut a slot into the top of the dowel to allow installation/removal with a screwdriver.
  2.  
  3. Install or connect the following:

    Alignment dowels
     
    Oil pan. Replace the dowels with bolts and tighten all bolts to 17 ft. lbs. (23 Nm).
     
    Flywheel access panel, if equipped
     
    Exhaust front pipe
     
    Front axle
     
    Engine oil dipstick
     
    Negative battery cable
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

4.7L Engine
2-Wheel Drive
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the upper fan shroud.
  6.  
  7. Remove the throttle body resonator and air inlet hose.
  8.  
  9. Remove the intake manifold.
  10.  
  11. Raise vehicle on hoist.
  12.  
  13. Disconnect exhaust pipe at exhaust manifolds.
  14.  
  15. Remove the structural dust cover using sequence shown.
  16.  
  17. Drain engine oil and remove oil filter.
  18.  
  19. Position suitable jack under engine.
  20.  
  21. Remove both left and right side engine mount through bolts.
  22.  
  23. Raise engine to provide clearance to remove oil pan.
  24.  
  25. Place blocks of wood between engine brackets and lower mounts to provide stability to engine.
    NOTE
    Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan.

  26.  
  27. Remove the oil pan mounting bolts and oil pan.
  28.  
  29. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine.
  30.  

To install:

Click image to see an enlarged view

Fig. Structural cover torque sequence-3.7L and 4.7L engines

  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 28 Nm (20 ft. lbs.).
  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. Raise the engine and remove the blocks of wood.
  8.  
  9. Lower engine and install both the left and right side engine mount through bolts. Tighten the nuts to 68 Nm (50 ft. lbs.).
  10.  
  11. Remove jack and install oil filter.
  12.  
  13. Install structural dust cover.
  14.  
  15. Install exhaust pipe onto exhaust manifolds.
  16.  
  17. Lower vehicle.
  18.  
  19. Install intake manifold.
  20.  
  21. Install throttle body resonator and air inlet hose.
  22.  
  23. Install upper fan shroud.
  24.  
  25. Fill cooling system.
  26.  
  27. Fill engine oil.
  28.  
  29. Start engine and check for leaks.
  30.  

4-Wheel Drive
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    NOTE
    On 4wd vehicles, the front axle must be removed before the oil pan can be removed.

  2.  
  3. Remove the front axle from vehicle.
  4.  
  5. Remove the structural dust cover using sequence shown.
  6.  
  7. Drain the engine oil and remove oil filter.
  8.  
  9. Remove the oil pan mounting bolts and oil pan.
  10.  
  11. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine.
  12.  

To install:

Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. Bedplate bolt tightening sequence-4.7L engine



Click image to see an enlarged view

Fig. 4.7L engine bedplate bolt torque sequence

  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 28 Nm (20 ft. lbs.).
  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. Install structural dust cover.
  8.  
  9. Install oil filter.
  10.  
  11. Install front axle.
  12.  
  13. Lower vehicle.
  14.  
  15. Fill engine oil.
  16.  
  17. Start engine check for leaks.
  18.  

5.9L 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:

    Oil filter
     
    Starter motor
     
    Cooler lines
     
    Oil level sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Exhaust Y-pipe
     
    Oil pan

    Click image to see an enlarged view

    Fig. Oil pan alignment dowels-3.9L, 5.9L engines

     

  6.  

To install:

  1. Install or connect the following:

    Oil pan, using a new gasket. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Exhaust Y-pipe
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Oil level sensor connector
     
    Cooler lines
     
    Starter motor
     
    Oil filter
     

  2.  
  3. Fill the crankcase.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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