Jeep Wrangler/YJ 1987-1995 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



2.5L Engine
1987-89 VEHICLES

See Figure 1

  1. Disconnect the battery ground.
  2.  
  3. Raise and support the vehicle on jackstands.
  4.  
  5. Drain the oil.
  6.  


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. Disconnect the exhaust pipe at the manifold.
  2.  
  3. Remove the starter.
  4.  
  5. Remove the bellhousing access plate.
  6.  
  7. Unbolt and remove the oil pan.
  8.  

To install:
  1. Clean the gasket surfaces thoroughly.
  2.  
  3. Install a replacement seal at the bottom of the timing case cover and at the rear bearing cap.
  4.  
  5. Using new gaskets coated with sealer, install the pan and torque the bolts to 10 ft. lbs. (14 Nm).
  6.  
  7. Install all other parts in reverse order of removal.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Oil pan gaskets and seals-1987-91 2.5L, 1987-90 4.2L and 1991 4.0L engines

1990-91 VEHICLES

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 2: Oil pan removal

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the engine oil.
  6.  
  7. Disconnect the exhaust pipe at the manifold.
  8.  
  9. Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the bellhousing access cover.
  14.  
  15. Position a jackstand directly under the vibration damper. Place a piece of wood between the jack and the vibration damper.
  16.  
  17. Remove the engine mount bolts/nuts. Using the jack, raise the engine until there is enough room to remove the oil pan.
  18.  
  19. Remove the oil pan bolts and remove the oil pan by sliding it to the rear.
  20.  
  21. Clean all sealant and old gasket material from the oil pan and cylinder block mating surfaces. Thoroughly clean the oil pan.
  22.  

To install:
  1. Install a replacement front seal on the timing case cover and apply a generous amount of suitable liquid gasket material to the recesses in the end tabs.
  2.  
  3. Cement the replacement oil pan side gaskets into position on the cylinder block. Apply a generous amount of suitable liquid gasket material to the end tabs of the gaskets.
  4.  
  5. Coat the inside curved surface of the replacement oil pan rear seal with soap. Apply a generous amount of suitable liquid gasket material to the gasket contacting surface of the seal end tabs.
  6.  
  7. Install the seal in the recess of the rear main bearing cap, making sure it is fully seated.
  8.  
  9. Apply engine oil to the oil pan contacting surface of the front and rear oil pan seals.
  10.  
  11. Install the oil pan and bolts. Tighten the 1 / 4 in. bolts to 80 inch lbs. (9 Nm) and the 5 / 16 in. bolts to 11 ft. lbs. (15 Nm).
  12.  
  13. Lower the engine and install the engine mount bolts/nuts. Lower the jack and remove the piece of wood.
  14.  
  15. Install the bellhousing access cover.
  16.  
  17. Install the starter.
  18.  
  19. Connect the exhaust pipe to the hanger and the exhaust manifold.
  20.  
  21. Install the oil pan drain plug and tighten to 25 ft. lbs. (34 Nm).
  22.  
  23. Lower the vehicle.
  24.  
  25. Fill the crankcase to the proper level with the recommended oil.
  26.  
  27. Connect the negative battery cable. Start the engine and check for leaks.
  28.  

1992-95 VEHICLES

See Figures 3, 4 and 5



Click image to see an enlarged view

Fig. Fig. 3: Fabricate alignment dowels from 1/4 in. bolts-1992-95 2.5L and 4.0L engines



Click image to see an enlarged view

Fig. Fig. 4: Position of dowels in cylinder block-1992-95 2.5L and 4.0L engines



Click image to see an enlarged view

Fig. Fig. 5: Install 5/16 in. oil pan bolts at position "A''-1992-95 2.5L and 4.0L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the engine oil.
  6.  
  7. Disconnect the exhaust pipe at the manifold.
  8.  
  9. Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the bellhousing access cover.
  14.  
  15. Position a jackstand directly under the vibration damper. Place a piece of wood between the jack and the vibration damper.
  16.  
  17. Remove the engine mount through bolts. Using the jack, raise the engine until there is enough room to remove the oil pan.
  18.  
  19. Remove the oil pan bolts and remove the oil pan.
  20.  
  21. Clean all sealant and old gasket material from the oil pan and cylinder block mating surfaces. Thoroughly clean the oil pan.
  22.  

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.
  2.  
  3. Install 2 dowels in the timing case cover and the other 2 in the cylinder block. Slide the one-piece gasket over the dowels and onto the block and timing case cover.
  4.  
  5. Position the oil pan over the dowels and onto the gasket. Install the 1 / 4 in. pan bolts and tighten to 10 ft. lbs. (14 Nm). Install the 5 / 16 in. pan bolts and tighten to 13 ft. lbs. (18 Nm).
  6.  
  7. Remove the dowels and install the remaining 1 / 4 in. pan bolts. Tighten to 10 ft. lbs. (14 Nm).
  8.  
  9. Lower the engine and install the engine mount through bolts and nuts. Lower the jack and remove the piece of wood.
  10.  
  11. Install the bellhousing access cover.
  12.  
  13. Install the starter.
  14.  
  15. Connect the exhaust pipe to the hanger and the exhaust manifold.
  16.  
  17. Install the oil pan drain plug and tighten to 25 ft. lbs. (34 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Fill the crankcase to the proper level with the recommended oil.
  22.  
  23. Connect the negative battery cable. Start the engine and check for leaks.
  24.  

4.0L Engine

1991 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the engine oil.
  6.  
  7. Disconnect the exhaust pipe at the manifold.
  8.  
  9. Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the bellhousing access cover.
  14.  
  15. Position a jackstand directly under the vibration damper. Place a piece of wood between the jack and the vibration damper.
  16.  
  17. Remove the engine mount bolts/nuts. Using the jack, raise the engine until there is enough room to remove the oil pan.
  18.  
  19. Remove the oil pan bolts and remove the oil pan by sliding it to the rear.
  20.  
  21. Clean all sealant and old gasket material from the oil pan and cylinder block mating surfaces. Thoroughly clean the oil pan.
  22.  

To install:
  1. Install a replacement front seal on the timing case cover and apply a generous amount of suitable liquid gasket material to the recesses in the end tabs.
  2.  
  3. Cement the replacement oil pan side gaskets into position on the cylinder block. Apply a generous amount of suitable liquid gasket material to the end tabs of the gaskets.
  4.  
  5. Coat the inside curved surface of the replacement oil pan rear seal with soap. Apply a generous amount of suitable liquid gasket material to the gasket contacting surface of the seal end tabs.
  6.  
  7. Install the seal in the recess of the rear main bearing cap, making sure it is fully seated.
  8.  
  9. Apply engine oil to the oil pan contacting surface of the front and rear oil pan seals.
  10.  
  11. Install the oil pan and bolts. Tighten the 1 / 4 in. bolts to 80 inch lbs. (9 Nm) and the 5 / 16 in. bolts to 11 ft. lbs. (15 Nm).
  12.  
  13. Lower the engine and install the engine mount bolts/nuts. Lower the jack and remove the piece of wood.
  14.  
  15. Install the bellhousing access cover.
  16.  
  17. Install the starter.
  18.  
  19. Connect the exhaust pipe to the hanger and the exhaust manifold.
  20.  
  21. Install the oil pan drain plug and tighten to 25 ft. lbs. (34 Nm).
  22.  
  23. Lower the vehicle.
  24.  
  25. Fill the crankcase to the proper level with the recommended oil.
  26.  
  27. Connect the negative battery cable. Start the engine and check for leaks.
  28.  

1992-95 VEHICLES

See Figures 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the engine oil.
  6.  
  7. Disconnect the exhaust pipe at the manifold.
  8.  
  9. Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the bellhousing access cover.
  14.  
  15. Position a jackstand directly under the vibration damper. Place a piece of wood between the jack and the vibration damper.
  16.  
  17. Remove the engine mount through bolts. Using the jack, raise the engine until there is enough room to remove the oil pan.
  18.  
  19. Remove the oil pan bolts and remove the oil pan.
  20.  
  21. Clean all sealant and old gasket material from the oil pan and cylinder block mating surfaces. Thoroughly clean the oil pan.
  22.  

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.
  2.  
  3. Install 2 dowels in the timing case cover and the other 2 in the cylinder block. Slide the one-piece gasket over the dowels and onto the block and timing case cover.
  4.  
  5. Position the oil pan over the dowels and onto the gasket. Install the 1 / 4 in. pan bolts and tighten to 10 ft. lbs. (14 Nm). Install the 5 / 16 in. pan bolts and tighten to 13 ft. lbs. (18 Nm).
  6.  
  7. Remove the dowels and install the remaining 1 / 4 in. pan bolts. Tighten to 10 ft. lbs. (14 Nm).
  8.  
  9. Lower the engine and install the engine mount through bolts and nuts. Lower the jack and remove the piece of wood.
  10.  
  11. Install the bellhousing access cover.
  12.  
  13. Install the starter.
  14.  
  15. Connect the exhaust pipe to the hanger and the exhaust manifold.
  16.  
  17. Install the oil pan drain plug and tighten to 25 ft. lbs. (34 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Fill the crankcase to the proper level with the recommended oil.
  22.  
  23. Connect the negative battery cable. Start the engine and check for leaks.
  24.  

4.2L Engine

  1. Raise the vehicle and drain the engine oil.
  2.  


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 starter motor.
  2.  
  3. Place a jack under the transmission bell housing. Disconnect the engine right support cushion bracket from the block and raise the engine to allow sufficient clearance for oil pan removal.
  4.  
  5. Remove the oil pan attaching bolts and remove the oil pan.
  6.  

To install:
  1. Remove the oil pan front and rear neoprene oil seals and the side gaskets. Thoroughly clean the gasket surfaces of the oil pan and the engine block. Remove all of the sludge and dirt from the oil pan sump.
  2.  
  3. Apply a generous amount of RTV silicone to the end tabs of a new oil pan front seal and install the seal to the timing case cover.
  4.  
  5. Cement new oil pan side gaskets into position on the engine block and apply a generous amount of RTV silicone to the side gasket contacting surface of the seal end tabs.
  6.  
  7. Install the seal in the recess of the rear main bearing cap, making sure that it is fully seated.
  8.  
  9. Coat the oil pan contacting surface of the front and rear oil pan seals with engine oil.
  10.  
  11. Install the oil pan and assemble the engine mount in the reverse order of removal.
  12.  

 
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