Liberty, Wrangler, 1997-2005

Oil Pan

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove air cleaner assembly.
  4.  
  5. Raise the vehicle on a hoist and drain the engine oil.
  6.  
  7. Loosen the engine mount through bolts.
  8.  
  9. Disconnect the exhaust pipe at the manifold.
  10.  
  11. Remove the structural collar, if equipped.
  12.  
  13. Remove the front axle mounting bolts, and lower the axle as far possible, if equipped.
  14.  
  15. Position Special Tool 8534, or equivalent, on the fender lip and align the slots in the brackets with the fender mounting holes.
  16.  
  17. Secure the brackets to the fender using four M6 X 1.0 X 25 mm flanged cap screws.
  18.  
  19. Tighten the thumbscrews to secure the sleeves to the support tube.
  20.  
  21. Secure the support tube in an upright position.
  22.  
  23. Assemble the flat washer, thrust bearing, hook and T handle.
  24.  
  25. Using the M10 X 1.5 X 40 mm capscrew supplied with the support fixture, secure the chain to the front cover and the hook.
  26.  
  27. Support the engine as needed.
  28.  
  29. Remove the oil pan attaching bolts.
  30.  
  31. Remove the oil pan.
  32.  
  33. Clean the oil pan and all gasket surfaces.

    Click image to see an enlarged view

    Fig. Oil pan gasket positioning-2.4L engines

  34.  

To install:

  1. Install the oil pan gasket to the block.
  2.  
  3. Apply a 3mm ( 1 / 8 inch) bead of Mopar® Engine RTV, or equivalent, at the oil pump to engine block parting line.
  4.  
  5. Install the pan and tighten the screws to 105 inch lbs. (12 Nm).
  6.  
  7. Lower the engine, and remove Special Tool 8534.
  8.  
  9. Tighten the engine mount through bolts.
  10.  
  11. Raise the front axle into position, and reinstall the front axle mounting bolts, if equipped.
  12.  
  13. Reconnect the exhaust pipe to the manifold.
  14.  
  15. Install the structural collar, if equipped.
  16.  
  17. Lower the vehicle.
  18.  
  19. Fill the engine crankcase with the proper oil to the correct level.
  20.  
  21. Reinstall the air cleaner assembly.
  22.  

2.5L & 4.0L Engines
  1. Disconnect negative cable from battery.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove the oil pan drain plug and drain the engine oil.
  6.  
  7. Disconnect the exhaust pipe at the exhaust manifold.
  8.  
  9. Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
  10.  
  11. Remove the starter motor.
  12.  
  13. Remove the engine flywheel and transmission torque converter housing access cover.
  14.  
  15. If equipped with an oil level sensor, disconnect the sensor.
  16.  
  17. Position a jack stand directly under the engine vibration damper.
  18.  
  19. Place a piece of wood (2 x 2) between the jack stand and the engine vibration damper.
  20.  
  21. Remove the engine mount through bolts.
  22.  
  23. Using the jack stand, raise the engine until adequate clearance is obtained to remove the oil pan.
  24.  
  25. Remove the oil pan bolts. Carefully slide the oil pan and gasket to the rear. If equipped with an oil level sensor, take care not to damage the sensor.
  26.  

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.  

2.8L Engine
4x2 Models
  1. Disconnect negative battery cable.
  2.  
  3. Remove engine cover.
    NOTE
    When installing engine support fixture, care must be taken not to damage the hood ajar switch mounted to the right inner fender.

  4.  
  5. Install engine support fixture, special tool #8534.
  6.  
  7. Raise vehicle on hoist.
  8.  
  9. Remove both front wheel and tire assemblies.
  10.  
  11. Remove front skid plate (if equipped).
  12.  
  13. Drain engine oil.
  14.  
  15. Disconnect the front drive shaft from the front drive axle.
  16.  
  17. Loosen both engine mount through bolts.
  18.  
  19. Lower vehicle.
  20.  
  21. Raise engine using support fixture, special tool #8534, until the viscous fan almost touches the fan shroud.
  22.  
  23. Raise vehicle on hoist.
  24.  
  25. Support the front cradle assembly with a suitable lifting devise.
  26.  
  27. Mark the front cradle to under body position to assure proper alignment during assembly.
  28.  
  29. Remove both inner rail cradle alignment bolts in the front wheel housing.
  30.  
  31. Loosen both power steering gear retaining bolts, leave the retaining nuts on the bolts.
  32.  
  33. Loosen power steering lines from cradle.
  34.  
  35. Remove both lower front strut bolts.
  36.  
  37. Loosen both front cradle mounting bolts.
  38.  
  39. Loosen both rear cradle mounting bolts.
  40.  
  41. Disconnect the oil sending unit harness connector.
  42.  
  43. Remove all oil pan retaining bolts, separate the oil level indicator tube from the pan and lower oil pan.
  44.  
  45. Lower front cradle using the suitable lifting devise until enough clearance is obtained to remove the oil pan.
  46.  

To install:

  1. Clean oil pan and sealing surfaces. Inspect oil pan and engine block.
  2.  
  3. Install a new oil filter on the oil pan.
    NOTE
    If installing a new oil pan, exchange the oil sending unit and install a new oil filter.

  4.  
  5. Install oil pan, gasket, oil pan retaining bolts, hand tight.
  6.  
  7. Push the oil pan against adaptor plate and tighten transmission to oil pan bolts first.
  8.  
  9. Tighten oil pan bolts to 130 inch lbs. (14.7 Nm), tighten oil pan nuts to 217 inch lbs. (24.5 Nm), beginning with the center bolts and then tighten the remaining fasteners in a clockwise rotation. Retighten the center two bolts again after all bolts are tighten to specification.
  10.  
  11. Raise the front cradle using a suitable lifting devise and align the cradle with the underbody marks made during the removal procedure.
  12.  
  13. Torque the cradle mounting bolts to 90 lbs. ft. (122 Nm).
  14.  
  15. Torque the cleves bolts to 100 ft. lbs. (136 Nm).
  16.  
  17. Torque the inner rail mounting bolts to 35 lbs. ft. (47 Nm).
  18.  
  19. Torque the steering gear mounting bolts to 120 lbs. ft. (162 Nm).
  20.  
  21. Remove the cradle support devise and lower the vehicle.
  22.  
  23. Lower the engine using support fixture, special tool #8534, until the engine mount through bolts are seated in the cradle.
  24.  
  25. Raise the vehicle.
  26.  
  27. Torque engine mount through bolts to 65 lbs. ft. (88 Nm).
  28.  
  29. Connect the oil sending unit harness connector.
  30.  
  31. Install front axle skid plate (if equipped).
  32.  
  33. Install both front wheel and tire assemblies and tighten to 85-115 lbs. ft. (115-155 Nm).
    NOTE
    When removing engine support fixture, care must be taken not to damage the hood ajar switch mounted to the right inner fender well (if equipped).

  34.  
  35. Lower the vehicle and remove the engine support fixture.
  36.  
  37. Refill engine to proper level with the correct viscosity engine oil.
  38.  
  39. Connect negative battery cable.
  40.  
  41. Start engine and inspect for leaks.
  42.  
  43. Install engine cover.
  44.  
  45. Perform complete front wheel alignment.
  46.  

4x4 Models
  1. Disconnect Battery.
  2.  
  3. Install Engine Support Fixture, special Tool 8534.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Remove front wheel and tire assemblies.
  8.  
  9. Remove skid plate (if equipped).
  10.  
  11. Drain engine oil.
  12.  
  13. Remove engine to transmission structural cover, (if equipped).
  14.  
  15. Remove transmission oil cooler line bracket.
  16.  
  17. Remove the front axle assembly from the vehicle.
  18.  
  19. Loosen both engine mount through bolts.
  20.  
  21. Lower the vehicle.
    NOTE
    It is not necessary to remove the viscous fan , or fan shroud, for oil pan removal.

  22.  
  23. Raise the engine using Engine Support Fixture, special Tool 8534, until the viscous fan almost touches the fan shroud.
  24.  
  25. Raise the vehicle.
  26.  
  27. Remove the oil pan bolts.
  28.  
  29. Separate the oil pan from the engine.
  30.  
  31. Remove the nuts and bolt holding the oil pump pick-up tube, and windage tray in place.
    NOTE
    It will be necessary to move the oil pan from side to side to gain access to these fasteners.

  32.  
  33. Drop the oil pump pick-up tube into the oil pan, and remove the oil pan, pick-up tube, and the windage tray, as an assembly, from the front of the vehicle.
  34.  

To install:

  1. Inspect oil pan gasket for defects, and replace if necessary.
  2.  
  3. Clean the oil pan and block gasket mating surfaces.
  4.  
  5. Drop the oil pump pick-up tube into the oil pan, and install the oil pan, pick-up tube, and the windage tray, as an assembly, from the front of the vehicle.
  6.  
  7. Install the windage tray, then the oil pump pick-up tube, and the nuts and bolt holding the oil pump pick-up tube, in place.
    NOTE
    It will be necessary to move the oil pan from side to side to gain access to these fasteners.

  8.  
  9. Torque the pick-up tube fasteners.
  10.  
  11. Install the oil pan.
  12.  
  13. Install and torque the oil pan bolts.
  14.  
  15. Install the engine to transmission structural cover, (if equipped).
  16.  
  17. Lower the vehicle.
  18.  
  19. Lower the engine using Engine Support Fixture, special Tool # 8534.
  20.  
  21. Remove the Engine Support Fixture, special Tool # 8534.
  22.  
  23. Raise the vehicle.
  24.  
  25. Tighten both engine mount through bolts.
  26.  
  27. Install the transmission oil cooler line bracket.
  28.  
  29. Install the front axle assembly to the vehicle.
  30.  
  31. Install the skid plate (if equipped).
  32.  
  33. Install the front wheel and tire assemblies.
  34.  
  35. Lower the vehicle.
  36.  
  37. Refill engine oil.
  38.  
  39. Reconnect battery.
  40.  
  41. Start engine, and check for leaks.
  42.  

3.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Engine from the vehicle
     
    Oil pan
     
    Oil pump pickup tube
     
    Oil pan gasket
     

  4.  
  5. Installation is the reverse of removal. Torque the bolts, in sequence, to 11 ft. lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-3.7L

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  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 11 ft. lbs. (15 Nm) 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.  

 
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