Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Raise the front of the vehicle and support it safely using jackstands. Remove the plug and drain the engine oil from the pan and crankcase.
  2.  
  3. Disconnect the fasteners from the exhaust manifold flange and the pipe rear flange, then remove the front exhaust pipe and gaskets from the vehicle.
  4.  
  5. Remove the engine stiffening bracket and the flywheel cover.
  6.  
  7. Remove the right wheel and splash shield, then loosen the 4 front motor mount bolts. Back the bolts out about 1 / 2 in. (12mm).
  8.  
  9. Remove all the oil pan bolts. For vehicles with a manual transaxle, an 8mm flex socket may be used to access the rear oil pan bolts located next to the flywheel.
  10.  
  11. Using SA9123E, or an equivalent RTV cutter tool, separate the oil pan from the engine. Drive the tool around the pan to shear the RTV seam, then tap the pan sideways with a rubber mallet to loosen.
  12.  
  13. Pry the engine mount away from the engine as necessary and remove the oil pan. Be careful not to damage or score component surfaces when prying.
  14.  

To install:
  1. Carefully clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. Apply a 0.16 in. (4mm) bead of RTV sealer to the pan flange. Make sure the RTV is applied to the inner side of the flange from the bolt holes as shown.
  4.  
  5. Install the oil pan within 3 minutes of RTV application and tighten the bolts to 80 inch lbs. (9 Nm).
  6.  
  7. Tighten the front mount bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the right splash shield and wheel.
  10.  
  11. Install the engine stiffening bracket and the flywheel cover.
  12.  
  13. Install the exhaust pipe. Tighten the pipe to manifold nuts in a crosswise pattern to 23 ft. lbs. (31 Nm) and the pipe to converter bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Remove the jackstands and carefully lower the vehicle, then fill the engine crankcase with clean engine oil immediately in order to prevent an attempt to start the engine without oil.
  16.  
  17. Start the engine and check for leaks.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: After loosening the four motor mount bolts, pry the mount away from the engine block for better clearance



Click image to see an enlarged view

Fig. Fig. 2: Apply a 0.16 in (4mm) bead of RTV to the oil pan flange to the inner side of the bolt holes

 
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