GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Oil Pan

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REMOVAL & INSTALLATION




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 your 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.

2.2L Engine

See Figure 1



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Fig. Fig. 1: Oil pan removal and installation-2.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Properly drain the engine oil into a suitable container.
  6.  
  7. Detach the starter bracket from the block, then remove the starter and position it aside.
  8.  
  9. Remove the flywheel cover.
  10.  
  11. Remove the oil filter. Make sure the gasket is removed with the filter.
  12.  
  13. Unfasten the oil pan bolts and nuts, then remove the oil pan from the vehicle. Remove and discard the oil pan gasket and seal(s).
  14.  
  15. Thoroughly clean the gasket mating surfaces.
  16.  

To install:
  1. Place a 0.079 in. (2mm) diameter bead of a suitable RTV sealer on the oil pan-to-block side sealing flanges. Apply a suitable bead of RTV sealant to the oil pan surface which fits to the engine front cover.
  2.  
  3. Using a new oil pan rear seal, apply a thin coat of RTV sealant on the ends down to the ears, then install the pan against the cylinder case and install the retaining bolts and nuts. Tighten the bolts and nuts to 124 inch lbs. (14 Nm).
  4.  
  5. Lubricate a new oil filter gasket with clean engine oil. Install the filter and tighten to 13 ft. lbs. (17 Nm).
  6.  
  7. Install the starter, as outlined in Engine Electrical of this repair guide.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Fill the crankcase with the proper type and amount of engine oil.
  12.  
  13. Connect the negative battery cable, then start the engine and check for leaks.
  14.  

2.3L Engine

See Figure 2



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Fig. Fig. 2: On the 2.3L engine, the block bolts are different from the other bolts

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the flywheel inspection cover.
  6.  
  7. Unfasten the splash shield-to-suspension support bolt. If equipped, Remove the exhaust manifold brace.
  8.  
  9. Remove the radiator outlet pipe-to-oil pan bolt.
  10.  
  11. Unfasten 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. Unfasten the oil pan retaining 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.  
  3. Place the spacer in its approximate installed position but allow clearance to tighten the pan bolt above it.
  4.  
  5. Tighten the pan-to-block bolts to 17 ft. lbs. (24 Nm) and the remaining bolts to 106 inch lbs. (12 Nm)
  6.  
  7. Install the spacer and stud.
  8.  
  9. Install the oil pan transaxle nut and bolt.
  10.  
  11. Install the splash shield to suspension support.
  12.  
  13. Fasten the radiator outlet pipe bolt.
  14.  
  15. Install the exhaust manifold brace, if removed.
  16.  
  17. Install the flywheel inspection cover.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Fill the crankcase with the proper type and amount oil.
  22.  
  23. Connect the negative battery cable, then start the engine and check for leaks.
  24.  

2.5L Engine

See Figures 3 and 4



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Fig. Fig. 3: Unfasten the retaining bolts, then remove the oil pan



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Fig. Fig. 4: Oil pan sealer application-2.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the coolant recovery bottle, engine torque strut, air cleaner and the air inlet.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. If equipped, loosen and move the A/C compressor from the bracket. Position the compressor aside, but do not disconnect the refrigerant lines.
  8.  
  9. Remove the oil level indicator and fill tube. 36462, or equivalent.
  10.  
  11. Raise and safely support the vehicle, drain the engine oil and remove the oil filter.
  12.  
  13. Remove the starter motor, flywheel cover and turn the front wheels to full right.
  14.  
  15. Remove the engine wiring harness retainers under the oil pan on the right and left sides.
  16.  
  17. Remove the right engine splash shield, front engine mount bracket bolts and nuts.
  18.  
  19. Remove the transaxle mount nuts. 36462, raise the engine about 2 in. (51mm).
  20.  
  21. Remove the front engine mount, bracket and loosen the frame bolts.
  22.  
  23. Remove the oil pan retaining bolts and oil pan.
  24.  

To install:
  1. Clean all gasket surfaces and apply RTV sealer to the oil pan and engine surfaces.
  2.  
  3. Install the oil pan and retaining bolts and tighten to 89 inch lbs. (10 Nm)
  4.  
  5. Install the frame bolts and tighten to 103 ft. lbs. (140 Nm)
  6.  
  7. Install the engine mount, bracket, lower the engine into position and install the transaxle mount nuts.
  8.  
  9. Install the engine mount nuts and bracket bolts.
  10.  
  11. Install the engine splash shield, wiring harness to the oil pan, flywheel cover and the starter motor.
  12.  
  13. Lower the vehicle and remove the engine support fixtures.
  14.  
  15. Install the oil level indicator and tube assembly.
  16.  
  17. If equipped, reinstall the A/C compressor to its original location.
  18.  
  19. Install the serpentine belt.
  20.  
  21. Install the air inlet, air cleaner, torque strut and coolant recovery bottle.
  22.  
  23. Connect the negative battery cable and fill the engine with the correct type and amount of oil.
  24.  
  25. Start the engine and check for leaks.
  26.  

2.8L and 3.1L Engine
1988-93 VEHICLES

See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Oil pan mounting-1993 3.1L engine shown

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt and the tensioner. -28467 or equivalent.
  4.  
  5. Raise and safely support the vehicle. Drain the engine oil.
  6.  
  7. Remove the right tire and wheel assembly. Remove the right inner fender splash shield.
  8.  
  9. Remove the steering gear pinch bolt. Remove the transaxle mount retaining bolts. Failure to disconnect intermediate shaft from rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This could cause a loss of steering control which could result inPersonal injury.
  10.  
  11. Remove the engine-to-cradle mounting nuts. Remove the front engine collar bracket from the block.
  12.  
  13. Remove the starter shield and the flywheel cover. Remove the starter.
  14.  
  15. Loosen, but do not remove the rear engine cradle bolts. Remove electrical connector at DIS sensor.
  16.  
  17. Unfasten the front cradle bolts and lower the front of the frame.
  18.  
  19. If equipped, remove secondary air injection pipe retaining nuts from the oil pan stud.
  20.  
  21. Unfasten the oil pan retaining bolts and nuts, then remove the oil pan. Remove and discard the gasket.
  22.  

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Install a new gasket on the oil pan. Apply silicon sealer to the portion of the pan that contacts the rear of the block.
  4.  
  5. Install the oil pan, nuts and retaining bolts. Tighten the rear bolts to 18 ft. lbs. (25 Nm), and the remaining nuts and bolts to 89 inch lbs. (10 Nm).
  6.  
  7. If equipped, install the secondary air injection pipe retaining nut to the oil pan stud.
  8.  
  9. Install the front cradle bolts and tighten the rear cradle bolts. Install DIS connector. Install the starter and splash shield. Install the flywheel shield.
  10.  
  11. Attach the collar bracket to the block, install the engine-to-cradle nuts. Install the transaxle mount nuts.
  12.  
  13. Install the steering pinch bolt. Install the right inner fender splash shield and tire assembly. Lower the vehicle.
  14.  
  15. Remove the engine support tool. Install the serpentine belt and tensioner.
  16.  
  17. Fill the crankcase to the correct level. Connect the negative battery cable. Run the engine to normal operating temperature and check for leaks.
  18.  

1994-96 VEHICLES

See Figures 6 and 7

Click image to see an enlarged view

Fig. Fig. 6: Oil pan mounting bolt locations-1996 3.1L engine shown



Click image to see an enlarged view

Fig. Fig. 7: Oil pan sealant application points-1996 3.1L engine shown

  1. Disconnect the negative battery cable.
  2.  

It may be necessary to remove the hood, with the help of an assistant, for access.

  1. Remove the engine mount strut and A/C compressor (if equipped) and the engine mount strut bracket assemblies.
  2.  
  3. Remove the electric cooling fan assemblies. -28467 and J 26462, or equivalent.
  4.  
  5. Raise and safely support the vehicle. Drain the engine oil.
  6.  
  7. Remove the front exhaust manifold pipe.
  8.  
  9. Remove the intermediate shaft bolt/screw.
  10.  
  11. Remove the oil level sensor.
  12.  
  13. Remove the engine splash shield.
  14.  
  15. Suitable support the drivetrain and front suspension with jack stands.
  16.  
  17. Remove the transaxle mount side frame retaining nuts from the drivetrain and suspension frame assembly.
  18.  
  19. Remove the engine mount side frame nuts from the drivetrain and suspension frame assembly.
  20.  
  21. Unfasten the rear drivetrain and front suspension frame bolts/screws.
  22.  
  23. If equipped, remove the lower drivetrain and front suspension frame bolts/screws.
  24.  
  25. Remove the engine mount assembly.
  26.  
  27. Remove the flywheel inspection cover.
  28.  
  29. Remove the starter, as outlined in Engine Electrical of this repair guide.
  30.  
  31. Disconnect the transaxle mount assembly from the oil pan.
  32.  
  33. Unfasten the side bolts and screws and the retaining bolts and screws, then remove the oil pan. Remove and discard the oil pan gasket.
  34.  

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Apply a small amount of sealer on either side of the rear main bearing cap, where the seal surface on the cap meets the cylinder block. Install a new gasket on the oil pan.
  4.  
  5. Position the oil pan and secure with the retaining bolts and screws. Tighten the retaining bolts and screws to 18 ft. lbs. (25 Nm) and the side bolts/screws using tool J 39505 or equivalent.
  6.  
  7. Fasten the transaxle mount assembly to the oil pan.
  8.  
  9. Install the starter motor, as outlined in Engine Electrical of this repair guide.
  10.  
  11. Install the flywheel inspection cover.
  12.  
  13. Install the engine mount assembly.
  14.  
  15. Carefully raise the drivetrain and front suspension assembly. Install the rear drivetrain and front suspension frame bolts/screws.
  16.  
  17. Fasten the engine mount frame side nuts to the drivetrain and front suspension frame assembly. Install the transaxle mount frame side nuts to the drivetrain and suspension frame assembly.
  18.  
  19. Remove the jackstands from the drivetrain and front suspension frame assembly.
  20.  
  21. Install the engine splash shield and the oil level sensor.
  22.  
  23. Install the intermediate steering shaft bolt/screw. Connect the front exhaust manifold pipe.
  24.  
  25. Carefully lower the vehicle.
  26.  
  27. Remove the engine support tools.
  28.  
  29. Install the electric cooling fan assemblies.
  30.  
  31. Install the engine mount strut and A/C compressor, bracket and the engine mount strut bracket.
  32.  
  33. If removed, install the hood assembly.
  34.  
  35. Fill the crankcase to the correct level. Connect the negative battery cable. Run the engine to normal operating temperature and check for leaks.
  36.  

3.4L Engine

See Figure 8



Click image to see an enlarged view

Fig. Fig. 8: Oil pan mounting-3.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support vehicle. Drain the engine oil into a suitable container.
  4.  
  5. Remove right front wheel and tire assemblies and the steering gear heat shield.
  6.  
  7. Unfasten the steering gear retaining bolts and support steering gear to body.
  8.  
  9. Separate right and left lower ball joints, using a suitable puller.
  10.  
  11. Disconnect power steering cooler line clamps at frame.
  12.  
  13. Safely support frame and remove engine mount nuts at frame.
  14.  
  15. Unfasten the frame retaining bolts and remove frame assembly.
  16.  
  17. Remove starter assembly and the flywheel cover.
  18.  
  19. Unfasten the oil pan retaining nuts and bolts, then remove the oil pan.
  20.  
  21. Remove and discard the old pan gasket. Clean all mating surfaces.
  22.  

To install:
  1. Install a new gasket, adding sealer to gasket next to rear main bearing cap. Position the oil pan and secure using the retaining bolts. Tighten the rear bolts to 18 ft. lbs. (24 Nm) and all other bolts and nuts to 89 inch lbs. (10 Nm).
  2.  
  3. Install the flywheel cover and starter motor.
  4.  
  5. Install the frame assembly and secure all bolts.
  6.  
  7. Install the engine mount nuts at frame. Remove frame support.
  8.  
  9. Connect the power steering cooler lines at frame.
  10.  
  11. Install the lower ball joints. Install steering gear to steering gear mounts.
  12.  
  13. Install steering gear retainer bolts and the heat shield.
  14.  
  15. Install the front tire and wheel assemblies and carefully lower the vehicle.
  16.  
  17. Connect the negative battery cable, then add the correct type and quantity of engine oil.
  18.  
  19. Start vehicle and check for leaks.
  20.  

3.8L Engine

See Figure 9



Click image to see an enlarged view

Fig. Fig. 9: Oil pan removal and installation-1996 3.8L engine shown

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine torque strut from the engine.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Disconnect the front exhaust pipe from the manifold.
  8.  
  9. Remove the right front wheel and tire assembly, then remove the inner fender splash shield.
  10.  
  11. Drain the engine oil into a suitable container, then remove the oil filter.
  12.  
  13. Disconnect the oil cooler pipes and allow to hang loose for access.
  14.  
  15. Remove both front engine mounts from the frame.
  16.  
  17. Remove the flywheel cover.
  18.  
  19. Raise the engine assembly safely, using a suitable jack.
  20.  
  21. If necessary, detach the oil level sensor electrical connector, then remove the sensor.
  22.  
  23. Unfasten the oil pan retaining bolts, then lower the oil pan and disconnect the oil pump screen assembly. Remove and discard the oil pan gasket.
  24.  
  25. Remove the oil pan and pump screen assembly.
  26.  

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Use a new oil pan gasket and install the oil pan and screen assembly to the engine.
  4.  

If the rear main bearing cap is being installed, then RTV sealant must be placed on the oil pan gasket tabs that insert into the gasket groove of the outer surface on the rear main bearing cap.

  1. Tighten the screen assembly bolts to 115 inch lbs. (13 Nm) and the oil pan retaining bolts to 124 inch lbs. (14 Nm). Do not overtighten.
  2.  
  3. If removed, install the oil level sensor and attach the connector.
  4.  
  5. Lower the engine and install the transaxle converter cover.
  6.  
  7. Install the engine mount nuts to the frame and tighten to 32 ft. lbs. (43 Nm).
  8.  
  9. Attach the oil cooler pipes and install the oil filter.
  10.  
  11. Install the inner fender splash shield and wheel assembly.
  12.  
  13. Connect the front exhaust pipe to the manifold.
  14.  
  15. Lower the vehicle, then install the engine torque strut to the engine.
  16.  
  17. Fill the crankcase with the proper amount and type of engine oil. Connect the negative battery cable, then start the engine and check for leaks.
  18.  

 
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