GM Malibu/Cutlass 1997-2000

Oil Pan

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REMOVAL & INSTALLATION



2.4L Engine
  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Properly drain the engine oil and the cooling system into suitable containers.
  4.  
  5. Remove the flywheel housing or transaxle converter cover, as applicable.
  6.  
  7. Remove the right front wheel and tire assembly, then remove the right splash shield.
  8.  
  9. Remove the serpentine drive belt.
  10.  
  11. Unfasten the A/C compressor lower retaining bolts.
  12.  
  13. Remove the transaxle-to-engine brace.
  14.  
  15. Disconnect the engine mount strut bracket.
  16.  
  17. Unfasten the radiator outlet pipe bolts, then remove the pipes from the oil pan.
  18.  
  19. Remove the exhaust manifold brace.
  20.  
  21. Unfasten the oil pan-to-flywheel cover bolt and nut.
  22.  
  23. Remove the flywheel cover stud for clearance.
  24.  
  25. Disconnect the radiator outlet pipe from the lower radiator hose and oil pan.
  26.  
  27. Detach the oil level sensor connector.
  28.  
  29. Unfasten the oil pan retaining bolts, then remove the pan and gasket. Inspect the gasket for damage. If it's OK, you can reuse it. No sealer is necessary.
  30.  



Click image to see an enlarged view

Fig. After removing the oil pan, inspect the gasket. If it's not damaged you can reuse it

To install:

  1. Position the gasket, then install the oil pan. Loosely install the retaining bolts.
  2.  
  3. Place the spacer in its approximate installed location by allowing clearance to tighten the pan bolt directly above the spacer. Tighten the oil pan bolts to the specifications given in the accompanying figure.
  4.  



Click image to see an enlarged view

Fig. Oil pan tightening specifications-2.4L engines

  1. Position the spacer into its proper position, then install the stud.
  2.  
  3. Fasten the oil pan-to-transaxle nut.
  4.  
  5. Attach the oil level sensor connector.
  6.  
  7. Connect the radiator outlet pipe to the oil pan and fasten with the retaining bolts.
  8.  
  9. Install the engine mount strut bracket.
  10.  
  11. Fasten the transaxle-to-engine brace.
  12.  
  13. Secure the A/C compressor bolts.
  14.  
  15. Install the serpentine drive belt.
  16.  
  17. Fasten the right splash shield, then install the wheel and tire assembly.
  18.  
  19. Install the flywheel housing or transaxle converter cover.
  20.  
  21. Fill the cooling system and engine crankcase with the correct type and amount of fluids.
  22.  
  23. Connect the negative battery cable.
  24.  

3.1L Engine
  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. 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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