Malibu 2001-2005

Oil Pan

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Removal & Installation



2.2L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Lower A/C compressor mounting bolt
     
    Oil pan mounting bolts
     
    Oil pan
     

  6.  

To install:

  1. Apply a 0.13 inch (3.5mm) bead of the GM P/N 12378521 sealant around the perimeter of the oil pan and oil suction port opening.
  2.  
  3. Install or connect the following:

    Oil pan. Tighten the bolts in sequence to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt sequence-2.2L engine

     
    Lower A/C compressor mounting bolt. Tighten the bolt to 37 ft. lbs. (50 Nm).
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the engine with oil to the correct level.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Lower A/C compressor mounting bolt
     
    Oil pan mounting bolts
     
    Oil pan
     

  6.  

To install:

  1. Apply a 0.13 inch (3.5mm) bead of the GM P/N 12378521 sealant around the perimeter of the oil pan and oil suction port opening.
  2.  
  3. Install or connect the following:

    Oil pan. Tighten the bolts in sequence to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Oil pan bolt sequence-2.2L engine

     
    Lower A/C compressor mounting bolt. Tighten the bolt to 37 ft. lbs. (50 Nm).
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the engine with oil to the correct level.
  6.  

3.1L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Evacuate and recover the A/C system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    WARNING
    DO NOT disconnect the refrigerant lines or allow the compressor to hang unsupported.



    Negative battery cable
     
    Accessory drive belt
     
    Upper and lower radiator hoses
     
    Right front wheel
     
    Inner fender splash shield
     
    Antilock Brake System (ABS) Wheel Speed Sensor (WSS) electrical connector
     
    Right front ball joint from the steering knuckle
     
    Right side outer tie rod end
     
    A/C compressor bolts and move the compressor aside
     



    Evaporator-to-accumulator A/C line
     
    Flywheel cover
     
    Engine cradle bolts
     
    Crankshaft balancer
     
    Starter motor
     
    Oil pan
     

  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pan mounting-3.1L and 3.5L engines

  1. Install or connect the following:
    NOTE
    Apply silicone sealer to the portion of the pan that contacts the rear of the block.



    Oil pan using a new gasket
     



    Oil pan bolts. Torque the bolts to 18 ft. lbs. (24 Nm) and the side bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Flywheel cover
     
    Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Evaporator-to-accumulator line
     
    Engine cradle bolts. Torque the bolts to 89 ft. lbs. (120 Nm).
     
    Ball joint to the steering knuckle using a new cotter pin. Torque the nut 48 ft. lbs. (60 Nm).
     
    Outer tie rod end. Torque the nut to 33 ft. lbs. (45 Nm).
     
    ABS wheel speed sensor electrical connector
     
    Inner fender splash shield
     
    Right front wheel
     
    Accessory drive belt
     
    Upper and lower radiator hoses
     
    Negative battery cable
     

  2.  
  3. Refill the crankcase.
  4.  
  5. Evacuate and recharge the A/C system.
  6.  
  7. Start the engine and check for leaks.
    NOTE
    Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

  8.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Inner fender splash shield
     
    Oil filter and oil filter adapter
     
    Catalytic converter
     
    ABS wheel speed sensor
     
    Right front ball joint from the steering knuckle
     
    Lower closeout panel
     
    A/C compress mounting bolts and position compress aside
     
    Engine-to-transmission support braces
     
    Oil level sensor
     

  6.  
  7. Support the engine using a jackstand or equivalent and remove the right side engine mounting bolts.
  8.  
  9. Loosen the left side cradle bolts.
  10.  
  11. Remove the cradle bolts from the right front and right rear.
  12.  
  13. Remove the starter motor.
  14.  
  15. Remove the oil pan mounting bolts.
  16.  
  17. Remove the oil pan.
  18.  

To install:

  1. Install or connect the following:
    NOTE
    Apply silicone sealant on the tabs that insert into the gasket groove on the outer surface of the mean bearing cap.



    Oil pan with a new gasket.
     



    Oil pan bolts. Tighten the bolts to 18 ft. lbs. (25 Nm) and the side bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor
     
    Flywheel inspection cover
     
    A/C compressor. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Engine cradle bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Ball joint to the steering knuckle
     
    ABS wheel speed sensor
     
    Engine-to-transmission support braces
     
    Catalytic converter
     
    Oil filter adapter and oil filter
     
    Inner fender splash shield
     
    Right front wheel
     
    Lower closeout panel
     
    Negative battery cable
     

  2.  
  3. Fill the engine with oil to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Inner fender splash shield
     
    Oil filter and oil filter adapter
     
    Catalytic converter
     
    ABS wheel speed sensor
     
    Right front ball joint from the steering knuckle
     
    Lower closeout panel
     
    A/C compress mounting bolts and position compress aside
     
    Engine-to-transmission support braces
     
    Oil level sensor
     

  6.  
  7. Support the engine using a jack stand or equivalent and remove the right side engine mounting bolts.
  8.  
  9. Loosen the left side cradle bolts.
  10.  
  11. Remove the cradle bolts from the right front and right rear.
  12.  
  13. Remove the starter motor.
  14.  
  15. Remove the oil pan mounting bolts.
  16.  
  17. Remove the oil pan.
  18.  

To install:

  1. Install or connect the following:
    NOTE
    Apply silicone sealant on the tabs that insert into the gasket groove on the outer surface of the mean bearing cap.



    Oil pan with a new gasket.
     



    Oil pan bolts. Tighten the bolts to 18 ft. lbs. (25 Nm) and the side bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor
     
    Flywheel inspection cover
     
    A/C compressor. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Engine cradle bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Ball joint to the steering knuckle
     
    ABS wheel speed sensor
     
    Engine-to-transmission support braces
     
    Catalytic converter
     
    Oil filter adapter and oil filter
     
    Inner fender splash shield
     
    Right front wheel
     
    Lower closeout panel
     
    Negative battery cable
     

  2.  
  3. Fill the engine with oil to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Place a suitable drain pan under the oil pan drain plug.
  8.  
  9. Remove the oil pan drain plug and drain the engine oil from the crankcase.
  10.  
  11. Reinstall the oil pan drain plug.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the air conditioning (A/C) compressor bolts and position the compressor aside.
  16.  
  17. Disconnect the oil level sensor electrical connector.
  18.  
  19. Remove the transaxle brace to oil pan bolts.
  20.  
  21. Remove the transaxle brace to transaxle bolt and remove the brace.
  22.  
  23. Remove the transaxle brace to oil pan lower bolt, if equipped with regular production option (RPO) M15.
  24.  
  25. Remove the oil pan bolts.

    Click image to see an enlarged view

    Fig. Oil pan removal , bolts (1) and (2) shown

  26.  
  27. Remove the oil pan.
  28.  
  29. Remove and discard the oil pan gasket.
  30.  
  31. Clean the oil pan sealing surfaces.
  32.  

To install:

  1. Apply sealer to both sides of the crankshaft rear main bearing cap. Press the sealer into the gap using a putty knife.
  2.  
  3. Apply sealer to both sides of the front cover and block mating area.
  4.  
  5. Install a new oil pan gasket.
  6.  
  7. Position the oil pan to the engine.
  8.  
  9. Install the oil pan bolts and note the following:

    Tighten the bolts (1) to 37 ft. lbs. (50 Nm).
     
    Tighten the bolts (2) to 18 ft. lbs. (25 Nm).
     

  10.  
  11. Install the transaxle brace to oil pan lower bolt, if equipped with (RPO) M15 and tighten to 37 ft. lbs. (50 Nm).
  12.  
  13. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug.
  14.  
  15. Install the transaxle brace to oil pan bolts. Tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Connect the oil level sensor electrical connector.
  18.  
  19. Position the A/C compressor install the bolts and tighten to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the starter and tighten mounting bolts to 32 ft. lbs. (43 Nm).
  22.  
  23. Install the positive battery cable nut to the starter solenoid. And tighten to 89 inch. lbs. (10 Nm).
  24.  
  25. Tighten the oil pan drain plug to 19 ft. lbs. (26 Nm).
  26.  
  27. Lower the vehicle.
  28.  
  29. Fill the crankcase.
  30.  
  31. Connect the negative battery cable.
  32.  

 
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