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PAN, Oil: Installation: AWD

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: OIL PAN SEALING - TYPICAL
GC0081736Courtesy of CHRYSLER LLC
  1. Clean oil pan and all mating surfaces.
  2. Apply a 1/8 inch bead of Mopar® Engine RTV GEN II at the parting line of the oil pump housing and the rear seal retainer.
    Fig 2: OIL PAN AND GASKET - 3.5L
    GC0095544Courtesy of CHRYSLER LLC
    1 - OIL PAN
    2 - BOLT
    3 - NUT
    4 - GASKET
    5 - ENGINE BLOCK
  3. Install the oil pan gasket (4) to the engine block (5).
  4. Install the oil pan (1) and attaching fasteners (2) and (3) finger tight.
    Fig 3: Removing/Installing Engine Oil Pan To Transmission Bolts - 3.5L
    GC0095543Courtesy of CHRYSLER LLC
    NOTE: Assure that the rear face of the oil pan is flush to the transmission bell housing when installing the oil pan.
  5. Install and pre-tighten four M10 horizontal rear oil pan to transmission bolts (1) to 1.4 N.m (12 in. lbs.).
    Fig 4: OIL PAN ALIGNMENT - AWD
    GC0095545Courtesy of CHRYSLER LLC
    1 - TIGHTEN FIRST
    2 - TIGHTEN SECOND
    3 - TIGHTEN THIRD
  6. First tighten the M8 (1) oil pan alignment bolt to 28 N.m (250 in. lbs.), then tighten bolt (2) to 28 N.m (250 in. lbs.).
  7. Tighten the remaining M8 bolts and M8 nuts to 28 N.m (250 in. lbs.) and the M6 bolts (3) to 12 N.m (105 in. lbs.).
  8. Tighten the four previously installed horizontal M10 oil pan to transmission bolts to 55 N.m (40 ft. lbs.).
    Fig 5: FLEX PLATE COVER
    GC0081733Courtesy of CHRYSLER LLC
    1 - COVER
    2 - BOLT
  9. Install the flex plate inspection cover (1) and tighten the fastener (2) to 11 N.m (97 in. lbs.).
    Fig 6: Oil Cooler & Hoses
    GC0081731Courtesy of CHRYSLER LLC
  10. Install the oil cooler and attaching fastener (if equipped) and tighten to 61 N.m (45 ft. lbs.). See Engine/Lubrication/COOLER, Oil - Installation .
  11. Install the engine oil filter (3). Tighten filter to 12 N.m (106 in. lbs.).
    Fig 7: FRONT DRIVE AXLE HOUSING
    GC0095542Courtesy of CHRYSLER LLC
    1 - BRACKET
    2 - BOLT
    3 - DRIVE AXLE HOSING
    4 - FRONT DRIVE SHAFT SHIELD
  12. Raise and support the engine with a jack stand.
  13. Install the front drive axle housing (3). Tighten mounting bolts to 65 N.m (48 ft. lbs.).
  14. Install the axle assembly support bracket (1) and tighten the bolts (2) to 28 N.m (21 ft. lbs.).
  15. Lower the engine and remove the jack stand.
    Fig 8: RETURN HOSE ROUTING CLIPS
    GC0080564Courtesy of CHRYSLER LLC
  16. Install the front stabilizer bar to cradle. Refer to Front Suspension/Front/STABILIZER BAR, Front - Installation .
  17. Install the engine mount to front cradle fasteners. Tighten the fasteners to 75 N.m (55 ft. lbs.).
  18. Position and install the power steering hose (3) to cradle hold downs (1).
    Fig 9: RIGHT HAND CATALYTIC CONVERTER
    GC0080336Courtesy of CHRYSLER LLC
  19. Install the right catalytic converter. Refer to Exhaust System/CONVERTER, Catalytic - Installation .
    Fig 10: RIGHT FRONT DRIVE AXLE AND AXLE HOUSING
    GC0095541Courtesy of CHRYSLER LLC
    1 - BRACKET
    2 - RIGHT FRONT DRIVE AXLE
    3 - AXLE HOUSING
    4 - FRONT DRIVE SHAFT HEAT SHIELD
  20. Install the front propeller shaft and the front propeller shaft heat shield (4). Refer to Differential and Driveline/Propeller Shaft - Installation .
    Fig 11: LEFT DRIVE AXLE AND INTERMEDIATE SHAFT
    GC0095540Courtesy of CHRYSLER LLC
    1 - FASTENER
    2 - LEFT FRONT DRIVE AXLE
    3 - INTERMEDIATE SHAFT HOUSING
    4 - OIL PAN
  21. Install the left front drive axle intermediate shaft housing (3) and support bracket. Refer to Differential and Driveline/Front Axle/DISCONNECT, Front Axle - Installation .
    Fig 12: HOSES AT AWD GEAR
    GC0080536Courtesy of CHRYSLER LLC
    NOTE: Always use a NEW O-ring on the ends of the steering hoses.
  22. Lubricate the NEW O-rings with clean power steering fluid.
  23. Install the return hose (1) and pressure hose (3) to the steering gear (2). Tighten the tube nuts to 47 N.m (35 ft. lbs.).
    Fig 13: LEFT DRIVE AXLE AND INTERMEDIATE SHAFT
    GC0095540Courtesy of CHRYSLER LLC
    1 - FASTENER
    2 - LEFT FRONT DRIVE AXLE
    3 - INTERMEDIATE SHAFT HOUSING
    4 - OIL PAN
  24. Install the right and left front axle shafts (2), hubs, brakes, wheels and tires. Refer to Differential and Driveline/Half Shaft - Installation .
  25. Install the belly pan. Refer to Frame and Bumpers/Under Body Protection/BELLY PAN - Installation .
    Fig 14: Engine Oil Level Indicator Tube Retaining Bolt And Indicator Tube
    GC0095539Courtesy of CHRYSLER LLC
  26. Lower the vehicle.
  27. Install the engine oil level indicator tube (2) and tighten the retaining bolt (1) to 12 N.m (105 in. lbs.).
    Fig 15: GENERATOR 3.5L
    GC0080020Courtesy of CHRYSLER LLC
  28. Position the generator bracket (4) and install the bracket bolt (3). Tighten the generator mounting bolt (2) to 65 N.m (48 ft. lbs.) and tighten the generator bracket bolt (3) to 54 N.m (40 ft. lbs.).
  29. Fill and bleed the power steering. Refer to Steering - Standard Procedure .
  30. Fill the engine crankcase with the proper oil to the correct level. Refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Specifications .
  31. Reconnect the negative battery cable.
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