GM Full Size Vans 1987-1997 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



4.3L Engines

See Figures 1, 2, 3, 4, 5 and 6

A one-piece oil pan gasket is used.

  1. Disconnect the negative battery cable. Raise the vehicle, support it safely, and drain the engine oil.
  2.  



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Fig. Fig. 1: Exploded view of the oil pan - 4.3L engines

  1. Remove the exhaust crossover pipe, if necessary.
  2.  
  3. Remove the oil cooler lines from the oil pan and from the adapter, if equipped.
  4.  
  5. Remove the oil filter and oil filter adapter, if equipped.
  6.  
  7. Remove the transmission oil cooler line bracket from the oil pan, if equipped (on models with automatic transmission only).
  8.  
  9. Remove the torque converter cover (on models with automatic transmission).
  10.  
  11. Remove the strut rods at the flywheel cover.
  12.  
  13. Remove the strut rod brackets at the front engine mountings, if necessary.
  14.  
  15. Remove the starter and starter opening shield, If equipped.
  16.  
  17. Remove the oil pan bolts, nuts and reinforcements.
  18.  
  19. Remove the oil pan and gaskets.
  20.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.



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Fig. Fig. 2: Loosen the exhaust pipe bolts for clearance



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Fig. Fig. 3: Loosen and remove the oil pan retaining bolts (a variety of ratchets extensions will be helpful)



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Fig. Fig. 4: If equipped, remove the oil pan reinforcements ...



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Fig. Fig. 5: ... then lower the pan from the vehicle



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Fig. Fig. 6: Remove the old gasket material and use a scraper to clean the mating surfaces

To install:
  1. Thoroughly clean all gasket surfaces and install a new gasket, using only a small amount of sealer at the front and rear corners of the oil pan.
  2.  
  3. Install the oil pan and new gaskets.
  4.  
  5. Install the oil pan bolts, nuts and reinforcements. On 1987-95 models, tighten the pan bolts to 100 inch lbs. (11 Nm) and tighten the nuts at the corners to 17 ft. lbs. (23 Nm). On 1996-97 models, tighten the bolts to 18 ft. lbs. (25 Nm) and then tighten the nuts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the transmission oil cooler line bracket (on models with automatic transmission).
  8.  
  9. Install oil filter adapter, oil cooler and the oil filter.
  10.  
  11. Install the starter and opening shield.
  12.  
  13. Install the strut rod brackets at the front engine mountings, if removed.
  14.  
  15. Install the strut rods at the flywheel cover, if removed.
  16.  
  17. Install the torque converter cover (on models with automatic transmission), if removed.
  18.  
  19. Install the exhaust crossover pipe, if removed.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fill the crankcase with the correct grade and amount of engine oil.
  24.  

5.0L and 5.7L Engines

See Figures 7 through 15



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Fig. Fig. 7: Remove the bolts from the oil filter adapter



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Fig. Fig. 8: Remove the oil filter adapter



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Fig. Fig. 9: Loosen the strut rod fasteners ...



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Fig. Fig. 10: ... then remove the strut rods

  1. Disconnect the negative battery cable. Drain the cooling system. Drain the engine oil.
  2.  
  3. If necessary, remove the engine oil dipstick.
  4.  
  5. Remove the oil cooler lines from the adapter.
  6.  
  7. If equipped, remove the exhaust crossover pipe.
  8.  
  9. If equipped with automatic transmission, remove the converter housing cover and the transmission oil cooler line retainer from the bracket.
  10.  
  11. Remove the starter brace and bolt and swing the starter aside.
  12.  
  13. Remove the oil pan and discard the gaskets.
  14.  



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Fig. Fig. 11: Remove the torque converter cover



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Fig. Fig. 12: Remove the oil pan bolts and nuts



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Fig. Fig. 13: Remove the oil pan reinforcements



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Fig. Fig. 14: Remove the oil pan from the vehicle



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Fig. Fig. 15: Remove the old gasket from both mating surfaces

  1. Installation is the reverse of removal. Clean all gasket surfaces and use new gaskets to assemble. Use gasket sealer to retain side gaskets to the cylinder block. Install a new oil pan rear seal in the rear main bearing cap slot with the ends butting the side gaskets. Install a new front seal in the crankcase front cover with the ends butting the side gaskets. On 1987-95 models, tighten the pan bolts to 100 inch lbs. (11 Nm) and tighten the nuts at the corners to 17 ft. lbs. (23 Nm). On 1996-97 models tighten the bolts to 18 ft. lbs. (25 Nm). Fill the engine with oil and check for leaks.
  2.  

7.4L Engines
1987-94 MODELS

See Figure 16

  1. Disconnect the battery.
  2.  
  3. If equipped, remove the oil pressure gauge tube.
  4.  
  5. Remove the distributor cap.
  6.  



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Fig. Fig. 16: Typical oil pan mounting - 7.4L engines

  1. Raise and support the front end on jackstands.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the flywheel strut rods and cover.
  6.  
  7. Remove the oil cooler lines from the filter housing.
  8.  
  9. Remove the starter assembly.
  10.  
  11. Support the engine with a floor jack.
  12.  


WARNING
Do not place the jack under the pan, sheet metal or pulley!

  1. Remove the engine mount through-bolts.
  2.  
  3. Raise the engine just enough to remove the pan.
  4.  
  5. Remove the oil pan and discard the gaskets.
  6.  

To install:
  1. Clean all mating surfaces thoroughly.
  2.  
  3. Apply RTV gasket material to the front and rear corners of the gaskets.
  4.  
  5. Coat the gaskets with adhesive sealer and position them on the block.
  6.  
  7. Install the oil pan.
  8.  
  9. Install the pan bolts, clips and reinforcements. Tighten the pan-to-cover bolts to 70 inch lbs. (8 Nm); the pan-to-block bolts to 13 ft. lbs. (18 Nm).
  10.  
  11. Lower the engine onto the mounts.
  12.  
  13. Install the engine mount through-bolts.
  14.  
  15. Connect the oil cooler lines.
  16.  
  17. Install the starter assembly.
  18.  
  19. Install the flywheel cover and strut rods.
  20.  
  21. Install the oil pressure gauge tube.
  22.  
  23. Connect the battery.
  24.  
  25. Fill the crankcase with the correct grade and amount of engine oil.
  26.  

1995-97 MODELS
  1. Disconnect the negative battery cable and remove the oil level indicator and tube.
  2.  
  3. Raise the vehicle, support it safely with jackstands and drain the oil.
  4.  
  5. If necessary, remove the oil dipstick tube.
  6.  
  7. Remove the flywheel/torque converter cover.
  8.  
  9. Remove the exhaust crossover pipe.
  10.  
  11. Remove the oil filter and adapter, if equipped.
  12.  
  13. Remove the oil cooler line retainer from the bracket, if equipped.
  14.  
  15. Remove the transmission oil cooler line retainer from the bracket, if equipped.
  16.  
  17. Remove the starter assembly, if necessary.
  18.  
  19. Remove the oil pan bolts, nuts and strut rods, if equipped.
  20.  
  21. Remove the oil pan and gasket.
  22.  

To install:
  1. Thoroughly clean all gasket surfaces and install a new gasket, using only a small amount of sealer at the front and rear corners of the oil pan.
  2.  
  3. Install the oil pan and new gaskets.
  4.  
  5. Install the oil pan bolts, nuts and strut rods. On 1995 model tighten the bolts to 100 inch lbs. (11 Nm) and the nuts to 16 ft. lbs. (22 Nm). On 1996-97 models, tighten the pan bolts and nuts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the transmission oil cooler line bracket (on models with automatic transmission).
  8.  
  9. Install oil filter adapter, oil cooler and the oil filter.
  10.  
  11. If removed, install the starter assembly.
  12.  
  13. Install the strut rod brackets at the front engine mountings, if removed.
  14.  
  15. Install the strut rods at the flywheel cover, if removed.
  16.  
  17. Install the torque converter cover (on models with automatic transmission), if removed.
  18.  
  19. Install the exhaust crossover pipe, if removed.
  20.  
  21. Install the oil dipstick tube.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the crankcase with the correct grade and amount of engine oil.
  26.  

6.2L and 6.5L Diesel Engines

See Figure 17

  1. Remove the engine cover.
  2.  
  3. Disconnect the batteries and remove the engine oil dipstick.
  4.  
  5. Remove the dipstick tube.
  6.  
  7. Raise and support the van. Drain the oil.
  8.  
  9. Remove the flywheel cover.
  10.  
  11. Remove the oil cooler lines at the filter base and the transmission cooler lines
  12.  
  13. If equipped, remove the cable clamps and cable from the oil pan.
  14.  
  15. On 1987-94 6.2L models, remove the transmission and flywheel.
  16.  



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Fig. Fig. 17: Oil pan - 6.2L engines

  1. Remove the oil pan.
  2.  

To install:
  1. Using new gaskets coated with sealer, position the oil pan on the block and install the bolts. Tighten the bolts to 89 inch lbs. (10 Nm), except for the two rear bolts. Tighten them to 17 ft. lbs. (23 Nm).
  2.  
  3. On 1987-94 6.2L models, install the transmission and flywheel.
  4.  
  5. Install the oil cooler lines at the filter base and connect the transmission cooler lines.
  6.  
  7. Install the flywheel cover.
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the batteries.
  12.  
  13. Install the engine oil dipstick tube and dipstick.
  14.  
  15. Change the oil and filter.
  16.  

 
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