GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Oil Pan

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REMOVAL & INSTALLATION



2.0L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the right front wheel assembly and the splash shield.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the exhaust pipe from the turbocharger/wastegate.
  10.  
  11. Unfasten the four retaining bolts, then remove the flywheel inspection cover.
  12.  
  13. Remove the oil pan attaching bolts and remove the oil pan, scraper and gasket.
  14.  
  15. The installation is the reverse of the removal procedure. Use a new gasket and apply sealant at the 4 engine block seams. Use thread locking compound on the bolt threads and tighten to 4 ft. lbs. (5 Nm), starting from the middle and working outward.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Place the oil pan gaskets and RTV in the appropriate order as shown-common 2.0L shown

  1. Fill the crankcase with oil to specification.
  2.  
  3. Connect the negative battery cable, then start the engine and check for leaks.
  4.  

2.3L Engine
1988-91 MODELS

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the flywheel inspection cover.
  6.  
  7. Remove the splash shield-to-suspension support bolt. Remove the exhaust manifold brace, if equipped.
  8.  
  9. Remove the radiator outlet pipe-to-oil pan bolt.
  10.  
  11. Remove the transaxle-to-oil pan nut and stud using a 7mm socket.
  12.  
  13. Gently pry the spacer out from between oil pan and transaxle.
  14.  
  15. Remove the oil pan bolts. Rotate the crankshaft, if necessary, and remove the oil pan and gasket from the engine.
  16.  
  17. Inspect the silicone strips across the top of the aluminum carrier at the oil pan-cylinder block-seal housing 3-way joint. If damaged, these strips must be repaired with silicone sealer. Use only enough sealer to restore the strips to their original dimension; too much sealer could cause leakage.
  18.  

To install:
  1. Thoroughly clean and dry the mating surfaces, bolts and bolt holes. Install the oil pan with a new gasket; do not use sealer on the gasket. Loosely install the pan bolts.
  2.  



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Fig. Fig. 2: Oil pan retaining bolt locations-1988-91 2.3L engine

  1. Place the spacer in its approximate installed position but allow clearance to tighten the pan bolt above it.
  2.  
  3. Tighten the pan-to-block bolts to 17 ft. lbs. (24 Nm) and the remaining bolts to 106 inch lbs. (12 Nm).
  4.  
  5. Install the spacer and stud.
  6.  
  7. Fasten the oil pan transaxle nut and bolt.
  8.  
  9. Connect the splash shield-to-suspension support.
  10.  
  11. Install the radiator outlet pipe bolt.
  12.  
  13. Connect the exhaust manifold brace, if removed.
  14.  
  15. Install the flywheel inspection cover.
  16.  
  17. Fill the crankcase with the proper type and amount oil.
  18.  
  19. Connect the negative battery cable and check for leaks.
  20.  

1992-95 MODELS

See Figures 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the right front wheel lugnuts.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the engine oil, then the coolant into suitable containers.
  8.  



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Fig. Fig. 3: After raising the vehicle, remove the plug and drain the engine oil

  1. Unfasten the retaining bolts, then remove the flywheel housing or transaxle converter cover, as applicable.
  2.  
  3. Remove the right front wheel and tire assembly, then remove the splash shield.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. Unfasten the A/C compressor from the bracket, making sure to suitably support it.
  8.  
  9. Remove the engine mount strut bracket.
  10.  
  11. Unfasten the radiator outlet pipe bolts.
  12.  
  13. Disconnect the A/C and radiator pipes from the oil pan.
  14.  
  15. Remove the exhaust manifold brace.
  16.  
  17. Unfasten the oil pan-to-flywheel cover bolt and nut. Remove the flywheel cover stud for clearance.
  18.  
  19. Detach the radiator outlet pipe from the lower radiator hose and oil pan.
  20.  
  21. If equipped, disengage the oil level sensor electrical connector.
  22.  



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Fig. Fig. 4: Remove the oil level sensor, which is mounted in the oil pan

  1. Unfasten the oil pan bolts, then lower the oil pan from the vehicle. Remove the gasket and discard if damaged. Clean the mating surfaces.
  2.  



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Fig. Fig. 5: Exploded view of the oil pan and gasket assembly-1992-95 2.3L

  1. Installation is the reverse of the removal procedure. Tighten the oil pan retaining bolts to the specifications shown in the accompanying figure.
  2.  



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Fig. Fig. 6: Insert and tighten all oil pan retaining bolts to specifications-2.3L engine

  1. Carefully lower the vehicle, fill the crankcase with the correct type and quantity of oil, then connect the negative battery cable. Start the engine and inspect for leaks.
  2.  

2.4L Engine

See Figures 7, 8 and 9

  1. Disconnect the negative battery cable. Loosen the right front wheel lugnuts.
  2.  
  3. Raise and safely support the front of the vehicle securely on jackstands.
  4.  
  5. Drain the engine crankcase.
  6.  



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Fig. Fig. 7: One gasket separates the oil pan from the cylinder block-2.4L engine



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Fig. Fig. 8: Towards the bottom of the engine oil pan is a drain plug

  1. Drain and recycle the engine coolant.
  2.  
  3. Unbolt and remove the flywheel housing or transaxle converter cover.
  4.  
  5. Remove the right front wheel.
  6.  
  7. Unbolt and remove the right front splash shield.
  8.  
  9. Remove the serpentine drive belt.
  10.  
  11. Remove the lower bolts for the A/C compressor but do not separate the lines attach to the compressor.
  12.  
  13. Remove the engine-to-transaxle brace.
  14.  
  15. Unbolt and extract the engine mount strut bracket.
  16.  
  17. Remove the radiator outlet pipe bolts and pull the pipes from the oil pan.
  18.  
  19. Unbolt and remove the exhaust manifold brace.
  20.  
  21. Loosen the flywheel cover-to-oil pan bolt and nut.
  22.  
  23. Remove the flywheel cover stud for clearance.
  24.  
  25. Separate the radiator outlet pipe from the lower hose and oil pan.
  26.  
  27. Disconnect the oil level sensor wiring harness from the switch.
  28.  
  29. Back-out each the oil pan bolt a few at a time except for two at either end of the pan. Keep two bolts in place and slowly remove them.
  30.  
  31. Using both hands, lower the pan. Remember there will be a small amount of fluid left in the pan.
  32.  

To install:
  1. Clean all gasket material from the block and pan. A razor edged scraper is a good tool for the job. Clean the inside of the pan of all gunk.
  2.  
  3. Place a new gasket on the oil pan and attach the pan to the block. Loosely install the bolts in their proper locations.
  4.  
  5. Place a spacer in its approximate installed location but allow clearance to tighten the pan bolt directly above the spacer.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: Oil pan bolt location and tightening specifications-2.4L engine

  1. Secure all the pan bolts to specifications. Refer to the illustration.
  2.  
  3. Position the spacer into its proper location then install the stud.
  4.  
  5. Install the oil pan-to-transaxle nut.
  6.  
  7. Attach the oil lever sensor wiring.
  8.  
  9. Connect the radiator outlet pipe to the lower radiator hose and oil pan.
  10.  
  11. Secure the radiator outlet pipes to the oil pan.
  12.  
  13. Install the engine mount strut bracket.
  14.  
  15. Attach the transaxle-to-engine brace. Tighten the bolts in sequence to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the A/C compressor lower bolts and secure.
  18.  
  19. Attach the right splash shield
  20.  
  21. Install the right front wheel.
  22.  
  23. Attach the flywheel housing or transaxle converter cover.
  24.  
  25. Lower the vehicle and secure the lugnuts.
  26.  
  27. Fill the cooling system and crankcase. Attach the negative battery cable.
  28.  
  29. Start the engine and top off all fluids. Check for leaks.
  30.  

2.5L Engine

See Figure 10

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle. Drain the engine oil.
  4.  
  5. Remove the exhaust pipe and hangers from the exhaust manifold and allow it to swing aside.
  6.  
  7. Detach the electrical connectors from the starter. Unfasten the starter-to-engine bolts, the starter and the flywheel housing inspection cover from the engine.
  8.  
  9. Unfasten the oil pan-to-engine bolts and the oil pan.
  10.  



Click image to see an enlarged view

Fig. Fig. 10: View of the oil pan and gasket assembly-2.5L engine

To install:
  1. Thoroughly clean the mating surfaces, bolts and bolt holes.
  2.  
  3. Apply RTV sealant to the oil pan flange, surrounding all bolt holes. Also, apply sealant to the engine at the front and rear seams.
  4.  
  5. Install the oil pan and tighten the bolts to 20 ft. lbs. (27 Nm) for vehicles through 1988. For 1989-91 vehicles, tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install the flywheel housing cover and the starter. Attach the starter electrical connector.
  8.  
  9. Install the exhaust pipe into its original position.
  10.  
  11. Fill the crankcase with oil to specification.
  12.  
  13. Connect the negative battery cable and check for leaks.
  14.  

3.0L and 3.3L Engines
ALL 3.0L AND 1988-91 3.3L ENGINES

See Figures 11, 12, 13 and 14

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil and remove the oil filter.
  6.  
  7. Remove the flywheel cover
  8.  
  9. For the 3.3L engine, remove the starter.
  10.  
  11. Unfasten the retaining bolts, then remove the oil pan, tensioner spring and formed rubber gasket.
  12.  



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Fig. Fig. 11: Using a suitable socket extension, remove the oil pan mounting bolts



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Fig. Fig. 12: You may have to maneuver the oil pan around the sub-frame



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Fig. Fig. 13: After the subframe is clear, lower the oil pan, then ...



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Fig. Fig. 14: ... remove and discard the gasket

  1. The installation is the reverse of the removal procedure. Tighten the oil pan-to-engine bolts to 88 inch lbs. (10 Nm) for the 3.0L engine or 10 ft. lbs. (14 Nm) for the 3.3L engine.
  2.  
  3. Fill the crankcase with the proper type and quantity of oil.
  4.  
  5. Connect the negative battery cable and check for leaks.
  6.  

1992-93 3.3L Engine

See Figure 15

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the lower flap and splash shield.
  8.  
  9. Disconnect the crankshaft pulley.
  10.  
  11. Remove the crankshaft position sensor cover.
  12.  
  13. Detach the A/C compressor electrical connector, then remove and support the compressor.
  14.  
  15. Disconnect the bolts at the front of the right suspension support.
  16.  
  17. Loosen, but do not remove, all the suspension support bolts so that the supports drop about 1.5 inch (38mm) at the front.
  18.  
  19. Remove the oil level sensor from the oil pan.
  20.  
  21. Remove the transaxle converter cover.
  22.  
  23. Unfasten the retaining bolts, then remove the oil pan. Remove and discard the gasket. Clean all mating surfaces.
  24.  



Click image to see an enlarged view

Fig. Fig. 15: View of the oil pan assembly-3.3L engine

  1. Installation is the reverse of the removal procedure. Make sure to use a new gasket. Tighten the oil pan retaining bolts to 10 ft. lbs. (14 Nm).
  2.  
  3. Carefully lower the car, fill the crankcase with the correct type and quantity of oil, then connect the negative battery cable. Start the engine and inspect for leaks.
  4.  

3.1L Engine

See Figure 16

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt.
  4.  
  5. If equipped, loosen, but do not remove, the upper A/C compressor bolts.
  6.  
  7. Loosen the right front wheel lugnuts.
  8.  
  9. Raise and safely support the front of the vehicle.
  10.  
  11. Drain the engine oil.
  12.  
  13. Remove the right front tire and wheel assembly.
  14.  
  15. Remove the right inner fender splash shield.
  16.  
  17. Disconnect the engine mount strut from the suspension support.
  18.  
  19. Pull out the cotter pin and remove the castle nut from the lower ball joint. Separate the joint from the steering knuckle.
  20.  
  21. Remove the right side sway bar link.
  22.  
  23. Detach the ABS sensor from the right subframe.
  24.  
  25. Unfasten the right side subframe mounting bolts then remove the subframe and control arm as an assembly.
  26.  
  27. Remove the lower A/C compressor mounting bolts and position the compressor aside. DO NOT disconnect the refrigerant lines or allow the compressor to hang unsupported.
  28.  
  29. Disconnect the engine mount strut bracket from the engine.
  30.  
  31. Remove the engine to transaxle brace.
  32.  
  33. Remove the oil filter.
  34.  
  35. Remove the starter.
  36.  
  37. Remove the flywheel inspection cover.
  38.  
  39. Unfasten the oil pan flange retaining bolts and the oil pan side retaining bolts, then remove the oil pan.
  40.  



Click image to see an enlarged view

Fig. Fig. 16: View of the oil pan mounting-3.1L engine

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Apply silicon sealer to the portion of the pan that contacts the rear of the block. On the block are cutouts, use a putty knife to insert silicon sealer into these crevices. Position a new gasket on the oil pan.
  4.  
  5. Position the oil pan and install the mounting bolts finger-tight.
  6.  
  7. With all the bolts in place, tighten the oil pan flange bolts to 18 ft. lbs. (25 Nm) and the oil pan side bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the flywheel inspection cover and the starter.
  10.  
  11. Coat the seal on the oil filter with clean engine oil, then install the filter on the engine.
  12.  
  13. Install the engine-to-transaxle brace and tighten the mounting bolts.
  14.  
  15. Install the engine mount strut bracket. Tighten the mounting bolt at the engine bracket to 85 ft. lbs. (115 Nm).
  16.  
  17. Place the A/C compressor in the mounting bracket, then tighten the lower mounting bolts.
  18.  
  19. Install the right side subframe and control arm assembly. Tighten the subframe mounting bolts to 89 ft. lbs. (120 Nm).
  20.  
  21. Install the right side sway bar link and secure.
  22.  
  23. Connect the ball joint to the steering knuckle and tighten the castle nut to 48 ft. lbs. (60 Nm). Install a new cotter pin.
  24.  
  25. Connect the ABS sensor to the right subframe assembly.
  26.  
  27. Connect the engine mount strut bracket and tighten the mounting bolt at the frame to 85-89 ft. lbs. (115-120 Nm).
  28.  
  29. Install the right inner fender well splash shield.
  30.  
  31. Install the right front tire and wheel assembly and tighten to specification.
  32.  
  33. Carefully lower the vehicle.
  34.  
  35. Install the serpentine belt.
  36.  
  37. Fill the crankcase to the correct level.
  38.  
  39. Connect the negative battery cable, start the vehicle and verify that there are no leaks.
  40.  

 
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