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Pan, Oil: Installation: AWD

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Fig 1: Locating Sealant On Oil Pan
GC0144972Courtesy of CHRYSLER GROUP, LLC
CAUTION:

Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage.

CAUTION:

Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  1. Clean the oil pan, timing chain cover, rear seal retainer and engine block mating surfaces with isopropyl alcohol in preparation for sealant application.
  2. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant to the oil pan as shown in illustration, in the following locations:
    • Oil pan to engine block flange (1)
    • Two timing cover to engine block T-joints (2)
    • Two rear seal retainer to engine block T-joints (3)
    Fig 2: Oil Pan Mounting Bolts (M8)
    GC0144968Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Make sure that the rear face of the oil pan is flush to the transmission bell housing before tightening any of the oil pan mounting bolts. A gap between the oil pan and the transmission could crack the oil pan or transmission casting.

  3. Install the oil pan to the engine block making sure the oil pan is flush to the transmission bell housing. Secure the oil pan to the engine block with nineteen M8 oil pan mounting bolts (1) finger tight.
    Fig 3: Transmission-To-Engine Oil Pan Bolts
    GC0144171Courtesy of CHRYSLER GROUP, LLC
  4. Install the four transmission to the engine oil pan bolts (1) and tighten to 55 N.m (41 ft. lbs.).
    Fig 4: Oil Pan Mounting Bolts (M8)
    GC0144968Courtesy of CHRYSLER GROUP, LLC
  5. Tighten the nineteen previously installed M8 oil pan mounting bolts (1) to 25 N.m (18 ft. lbs.).
    Fig 5: Rear Oil Seal Retainer Flange Bolts
    GC0144907Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Illustration shown with transmission removed for clarity.

  6. Install the two M6 bolts (1) to the rear oil seal retainer flange and tighten to 12 N.m (9 ft. lbs.).
    Fig 6: Rubber Plugs
    GC0144915Courtesy of CHRYSLER GROUP, LLC
  7. Install the two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 7: Crossmember & Bolts (AWD)
    GC0144962Courtesy of CHRYSLER GROUP, LLC
  8. Lower the rear of the engine and install the two bolts (2) to the rear engine mount isolator. Tighten the bolts to 65 N.m (48 ft. lbs.).
    Fig 8: Bolt & Transmission Cooling Lines
    GC0144918Courtesy of CHRYSLER GROUP, LLC
  9. Install the transmission cooling lines (2) and tighten the bolt (1) to 12 N.m (106 in. lbs.).
    Fig 9: Steering Gear Mounting Bolts
    GC0079709Courtesy of CHRYSLER GROUP, LLC
  10. Lift the steering gear (1) into the mounted position and install the steering gear lower mounting bolts (2 and 3). Install the upper mounting bolt (4) and nut. Tighten all bolts to 102 N.m (75 ft. lbs.).
    Fig 10: Steering Coupling
    GC0080527Courtesy of CHRYSLER GROUP, LLC

    Align splines and install the lower intermediate shaft coupling (2) to the steering gear shaft (3). Install a NEW  pinch bolt and tighten to 45 N.m (33 ft. lbs.).

    Fig 11: Stabilizer Bar Bushing & Retainer
    GC0079723Courtesy of CHRYSLER GROUP, LLC
  11. Raise the stabilizer bar to the engine cradle, placing bushings (1) into the mounted position.
  12. Install the bolts (2) securing each stabilizer bar isolator retainer (3) to the cradle. Tighten the bolts to 60 N.m (44 ft. lbs.).
    Fig 12: Removing/Installing Front Axle
    GC0081412Courtesy of CHRYSLER GROUP, LLC
  13. Install the front axle assembly (1) with propeller shaft, intermediate shaft, halfshafts, wheels, tires and exhaust pipe. Refer to INSTALLATION .
  14. If required, fill the front axle with the specified type and amount of gear lubricant.
    Fig 13: Lower Splash Shield & Fasteners
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  15. Position the belly pan and install the retainers (1).
  16. Lower the vehicle.
    Fig 14: Heater Core Inlet Tube, Oil Level Indicator & Bolts
    GC0144913Courtesy of CHRYSLER GROUP, LLC
  17. Install the oil level indicator (2) with bolt (1) tightened to 12 N.m (106 in. lbs.).
  18. Position the heater core inlet tube (4) and install two bolts (3) tightened to 12 N.m (106 in. lbs.).
  19. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
    Fig 15: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose Assembly & Fasteners
    GC0144029Courtesy of CHRYSLER GROUP, LLC
  20. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
  21. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
  22. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
  23. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
  24. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
    Fig 16: Engine Cover
    GC0144028Courtesy of CHRYSLER GROUP, LLC
  25. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
  26. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  27. Start and run the engine until it reaches normal operating temperature and check for leaks.
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