Oil Pan

REMOVAL & INSTALLATION

1990–94 Vehicles

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the oil pan drain plug and drain the engine oil into a suitable container.
4. After the oil has drained completely, install the drain plug and tighten to 33 ft. lbs. (45 Nm).
5. Disconnect and lower the exhaust pipe from the engine manifold.
6. Using the appropriate equipment, support the weight of the engine.
7. On FWD models, remove the retainer bolts and the center crossmember and AWD models, remove the left member.
8. Unfasten the oil pan bolts. Carefully the special tool or a thin prybar between the engine block and the oil pan. Lower and remove the oil pan from the vehicle.

   NOTE: Do not use a chisel, screwdriver or similar tool when removing the oil pan. Damage to engine components may occur.

   Fig. 1: Remove the oil pan by placing a brass bar at the corner of the tool and tap with a hammer

9. Inspect the oil pan for damage and cracks. Replace if faulty. While the pan is removed, inspect the oil screen for clogging, damage and cracks. Replace if faulty.

   Fig. 2: Exploded view of the oil pan and related components — 1990–94 2.0L AWD engines, others similar

   To install:

10. Using a wire brush or other tool, scrape clean all gasket surfaces of the cylinder block and the oil pan so that all loose material is removed. Clean sealing surfaces of all dirt and oil.
11. Apply sealant around the gasket surfaces of the oil pan in such a manner that all bolt holes are circled and there is a continuous bead of sealer around the entire perimeter of the oil pan.

    Fig. 3: Proper application of sealant on the oil pan gasket mating surfaces — 1990–94 vehicles

    NOTE: The continuous bead of sealer should be applied in a bead approximately 0.16 in. (4mm) in diameter.

12. Install the oil pan onto the cylinder block within 15 minutes after applying sealant. Install the fasteners and tighten to 4–6 ft. lbs. (6–8 Nm).
13. On FWD models, install the crossmember and tighten the crossmember mounting bolts to 72 ft. lbs. (100 Nm).
14. On AWD models, install the left member and tighten the forward retainer bolts to 72 ft. lbs. (100 Nm). Tighten the rearward left member bolts to 58 ft. lbs. (80 Nm).
15. Connect the exhaust pipe from the engine manifold with new gasket in place. Tighten the exhaust pipe to manifold flange nuts to 29 ft. lbs. (40 Nm). Install and tighten the support bolt to 29 ft. lbs. (40 Nm).
16. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.
17. Connect the negative battery cable. Start the engine and check for leaks.

1995–98 Vehicles

2.0L NON-TURBO ENGINE

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Drain the engine oil into a suitable container.
4. Once the oil has completely drained, install the plug and tighten to 25 ft. lbs. (34 Nm).
5. Remove the front exhaust pipe.
6. Remove the engine oil dipstick and tube assembly.
7. Remove the front plate.
8. Unfasten the oil pan mounting bolts, then remove the oil pan and gasket.

   Fig. 4: Exploded view of the oil pan and related components — 1995–98 2.0L non-turbo engine

   To install:

9. Apply sealant at the point where the engine block meets the oil pump.
10. Use a new gasket and install the oil pan. Tighten the mounting bolts to 8.9 ft. lbs. (12 Nm).
11. Install the front plate.
12. Install the front exhaust pipe.
13. Install the dipstick and tube assembly.
14. Safely lower the vehicle to the floor.
15. Refill the crankcase with oil to the proper level.
16. Connect the negative battery cable.
17. Start the engine and check for leaks.

2.0L TURBO ENGINE

1. Disconnect the negative battery cable.
2. Safely raise and support the vehicle.
3. Remove the front exhaust pipe.
4. Remove the exhaust pipe and muffler assembly.
5. Drain the engine oil into a suitable container. Once the oil has drained completely, tighten the plug to 29 ft. lbs. (39 Nm).
6. Remove the dipstick and tube.
7. For AWD vehicles, remove the transfer case assembly as follows:
   1. With the propeller shaft still installed, remove the transfer mounting bolt.
   2. Insert a suitable prytool in between the transfer case and transaxle, then remove the transfer case from the center shaft.
   3. Remove the transfer case from the center shaft. Do NOT tilt the transfer assembly to the rear or oil will leak out.
   4. After removing the transfer assembly, insert tool MB991193 or equivalent, to prevent the oil from leaking out. Use a piece of wire to suspend the transfer case from the body.

      Fig. 5: View of the transfer case with the tool installed to prevent oil from leaking out — 1995 — –98 2.0L turbo engines

8. Remove the bell housing cover.
9. Disconnect the oil return pipe from the oil pan.
10. Remove the oil pan mounting bolts. Tap the oil pan seal breaker MB998727 or equivalent between the oil pan and the engine block to break the seal and remove the oil pan.

    Fig. 6: Exploded view of the oil pan and sealant application — 1995–98 2.0L engine

    To install:

11. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant MD970389 or equivalent to the oil pan.
12. Clean the oil pan mounting bolt holes in the oil seal case.
13. Install the oil pan to the engine block. Tighten the mounting bolts to 5.1 ft. lbs. (6.9 Nm).
14. Use a new gasket and connect the oil return pipe to the oil pan.
15. Install the bell housing cover.
16. If equipped with AWD, install the transfer case assembly.
17. Install the dipstick and tube assembly.
18. Install the front exhaust pipe.
19. Install the exhaust pipe and muffler.
20. Install a new oil filter.
21. Safely lower the vehicle to the floor and add five quarts of oil to the crankcase.
22. Connect the negative battery cable.
23. Start the engine and check for leaks.

2.4L ENGINE

1. Remove the negative battery cable.
2. Raise and safely support the vehicle.
3. Drain the engine oil into a suitable container. When the oil has completely drained, install the plug and tighten to 29 ft. lbs. (39 Nm).
4. Remove the engine dipstick and tube assembly.
5. Remove the front exhaust pipe.
6. Remove the bell housing inspection cover.
7. Unfasten the bolts attaching the oil pan to the cylinder block, then using special tool, remove the oil pan assembly from the vehicle.

   Fig. 7: Oil pan sealer application points

   To install:

8. Make sure that the oil pan and cylinder block mating surfaces are free of any old sealing material. Apply the specified sealant or the equivalent.
9. Install the oil pan to the cylinder block and tighten the bolts to 5 ft. lbs. (7 Nm).
10. Reinstall the bell housing inspection cover. Tighten the bolts to 7 ft. lbs. (9 Nm).
11. Install the front exhaust pipe.
12. Reinstall the engine dipstick and tube assembly using a new O-ring.
13. Carefully lower the vehicle.
14. Refill the engine with oil. Reconnect the negative battery cable. Start the engine and check for leaks.