Sprinter 2005-2007

Oil Pan

Print

Removal & Installation



2.7L Engine
  1. Drain the engine oil.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the sway bar retaining bolts and swing sway bar down and out of the way.
  6.  
  7. Remove the wiring harness duct from the oil pan bolts and position out of the way.
  8.  
  9. Lower the vehicle and remove the turbocharger upper heat shield.
  10.  
  11. Connect Special Tool 8534 Engine Support Fixture using adapters no. 8534-16, to the engine lifting eye.

    Click image to see an enlarged view

    Fig. Connect Special Tool 8534 Engine Support Fixture using adapters no. 8534-16, to the engine lifting eye and raise engine slightly-2.7L Engine

  12.  
  13. Remove the engine mount bolts and raise the engine slightly.
  14.  
  15. Disconnect the oil level sensor.
  16.  
  17. Remove the transmission cooler lines from the oil pan bolts and carefully position the lines aside.
  18.  
  19. Remove the oil pan bolts.
    NOTE
    The bolts are different sizes. Mark the location of the bolts and keep them in order.

  20.  
  21. Remove oil pan and gasket.
  22.  

To install:

  1. Slide the oil pan and gasket into position.
  2.  
  3. Add sealant to the joints on the engine block, where indicated.

    Click image to see an enlarged view

    Fig. Add sealant to the joints on the engine block as indicated before installing the mounting bolts-2.7L Engine



    Click image to see an enlarged view

    Fig. Oil pan bolts: M8 x 40 (1), M8 x 50 (2), M6 x 85 (3), M6 x 20 (4), M6 x 35 (5), Transmission bell housing bolts (5)-2.7L Engine

  4.  
  5. Tighten the M6 bolts to 80 inch lbs. (9 Nm) and the M8 bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Tighten the transmission bellhousing-to-oil pan bolts to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the wiring harness duct.
  10.  
  11. Connect the oil level sensor.
  12.  
  13. Lower the vehicle.
  14.  
  15. Lower the engine until the engine mount and engine supports make contact.
  16.  
  17. Start and hand tighten the engine mount bolts.
  18.  
  19. Lower the engine the rest of the way and remove the engine support fixture.
  20.  
  21. Tighten the engine mount bolts to 61 ft. lbs. (83 Nm).
  22.  
  23. Install the sway bar and tighten bolts to 22 ft. lbs. (30 Nm).
  24.  
  25. Refill the engine with oil to the correct level.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  

3.5L Engines
Lower Oil Pan
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine oil dipstick and dipstick tube.
  6.  
  7. Remove the lower oil pan mounting bolts.
  8.  
  9. Use a bolt in the oil pan boss to carefully pull the lower oil pan from the upper oil pan.

    Click image to see an enlarged view

    Fig. Use a bolt (2) in the oil pan boss (1) to pull the lower oil pan (3) from the upper oil pan-3.5L Engine

  10.  

To install:

  1. Install the oil dipstick tube and tighten the mounting bolt to 80 inch lbs. (9 Nm).
  2.  
  3. Remove any sealant residues with an adhesive and sealant remover. Do not use any sharp-edged tools or abrasive paper as this can damage the sealing surfaces. Make sure the sealing surfaces are clean and dry before applying the RTV.
  4.  
  5. Apply Loctite® 7200 or equivalent to the mating surface of the lower oil pan.
  6.  
  7. Install the lower oil pan and tighten the mounting bolts in a crisscross pattern to 80 inch lbs. (9 Nm).
  8.  
  9. Install the oil dipstick.
  10.  
  11. Install the oil drain plug, if not already installed.
  12.  
  13. Refill the engine with oil to the correct level.
  14.  
  15. Connect the negative battery cable.
  16.  

Upper Oil Pan
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the lower oil pan.
  8.  
  9. Loosen the hose clamp bolt from the catalytic converter diesel particulate filter device at the connecting flange at the turbocharger.
  10.  
  11. Remove the bracket bolt for the catalytic converter diesel particulate filter unit.
  12.  
  13. Attach a suitable engine supporting shackle.
  14.  
  15. Detach the charge air hose upstream of the charge air cooler.
  16.  
  17. Detach the charge air hose on the engine charge air duct downstream of the charge air cooler.
  18.  
  19. Unscrew the bracket for the transmission oil lines on the right side of the oil pan.
  20.  
  21. Remove the transmission with the torque converter. For additional information, refer to the following section, -Automatic Transmission Assembly, Removal & Installation.-
  22.  
  23. Remove the end cover.
  24.  
  25. Remove the bolts that connect the left and right engine mount to the engine support.
  26.  
  27. Using a suitable engine lift, carefully raise the engine.
  28.  
  29. Remove the oil suction pipe.
  30.  
  31. Remove the refrigerant compressor bolt at the top section of the oil pan.
  32.  
  33. Remove the upper oil pan mounting bolts.
  34.  
  35. Remove the upper oil pan.
  36.  

To install:

  1. Install the oil suction pipe.
  2.  
  3. Install the upper oil pan and tighten the mounting bolts.

    Click image to see an enlarged view

    Fig. Upper oil pan mounting bolt locations-3.5L Engine

  4.  
  5. Connect the oil level switch connector.
  6.  
  7. Install the oil dipstick guide tube.
  8.  
  9. Install the bolt from catalytic converter diesel particulate filter unit bracket
  10.  
  11. Tighten the bolt on hose clamp from catalytic converter diesel particulate filter device at connecting flange from turbocharger.
  12.  
  13. Lower the engine into place.
  14.  
  15. Install the bolts connecting the left and right engine mount to the engine support.
  16.  
  17. Remove the engine supporting shackle.
  18.  
  19. Install the charge air hose upstream of charge air cooler.
  20.  
  21. Install the charge air hose on engine charge air duct downstream of charge air cooler.
  22.  
  23. Install the bracket for transmission oil lines on the oil pan on the right.
  24.  
  25. Install the transmission with the torque converter.
  26.  
  27. Install the end cover.
  28.  
  29. Install the refrigerant compressor bolt at oil pan top section.
  30.  
  31. Install the lower oil pan.
  32.  
  33. Install the air intake assembly.
  34.  
  35. Connect negative battery cable.
  36.  
  37. Refill the engine with oil to the correct level.
  38.  
  39. Start the engine and check for leaks.
  40.  

 
label.common.footer.alt.autozoneLogo