Dodge Repair: oil pan removal, transmission oil cooler, fan shroud


Question
Hello, I have a 1999 Dodge fullsize 1500 van. I need to replace the oil pump. I am unable to remove the oil pan. I have unbolted the motor and have jacked up the motor at the balancer but I still lack about 2 inches clearance to remove the pan. Any ideas?

Answer
OIL PAN
REMOVAL
Disconnect battery negative cable.
Remove engine oil dipstick.
Remove air cleaner inlet duct.
Unbolt the engine controller from the cowl and secure out of the way. DO NOT DISCONNECT.
Remove upper cooling fan shroud fasteners.
Remove engine cover. Refer to procedure in this group.
Raise vehicle on hoist.
Drain engine oil.
Remove transmission oil cooler lines from the oil pan mounting clip.
Remove engine to transmission support braces.
Remove starter motor.
Remove transmission inspection cover.
Remove left and right engine mount insulator nuts Engine Mount Insulator - Right Side Engine Mount Insulator - Left Side
Remove the oil pan fasteners.
Remove the oil pan from the vehicle. Note: The crankshaft may have to be rotated for the oil pan to clear the #1&2 journal counterweight on removal
CLEANING
Clean the cylinder block and oil pan mating surfaces.
Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of the screen.
INSPECTION
Inspect the oil pan drain plug and hole for stripped or damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary.
INSTALLATION
Fabricate four alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver Fabrication of Alignment Dowels
Install the dowels in the cylinder block Position of Dowels in Cylinder Block
Apply a small amount of Mopar® Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block.
Slide the one piece gasket over the dowels and onto the block.
Position the oil pan over the dowels and onto the gasket.
Install the oil pan bolts. Tighten the bolts to 24 N·m (215 in. lbs.)
Remove the dowels. Install and tighten the remaining pan bolts to 24 N·m (215 in. lbs.)
Install and tighten the oil pan drain plug to 34 N·m (25 ft. lbs.)
Lower the engine while aligning the engine mount insulators with the brackets.
Install the mount insulator nuts and tighten to 102 N·m (75 ft. lbs.)
Install the transmission inspection cover.
Install the starter motor.
Install the engine to transmission support brackets.
Install the transmission oil cooler lines into the mounting clips.
Lower the vehicle.
Install the upper cooling fan shroud.
Fasten the controller to the cowl.
Install the air cleaner inlet duct.
Install the engine oil dipstick.
Fill the crankcase with engine oil.
Connect the battery negative cable.
Start engine and check for leaks.