Oil Pan: Service and Repair

Oil Pan Replacement

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the oil level indicator tube.







3. Remove the front shock upper retaining nuts.
4. Remove the tires and wheels. Refer to Vehicle Lifting.








5. Remove the engine shield bolts and shield.
6. Drain the engine oil.
7. Drain the differential oil.
8. Remove the steering gear.







9. Remove the left and right antilock brake system (ABS) wiring harnesses from the retainers.







10. Disconnect the wheel speed sensor electrical connectors.







11. Remove the brake hose retaining bolts from the frame.







12. Disconnect the sway bar link pins from the lower control arm on both sides.







13. Place an adjustable jack stand under the lower control arm.
14. Remove the upper ball joint pinch bolt and nut.
15. Disconnect the upper control arm from the upper ball joint.
16. lower and remove the adjustable jack stand allowing the suspension to hang.
17. Remove the left wheel driveshaft.
18. Remove the right wheel driveshaft from the intermediate shaft bearing assembly only. It is not necessary to remove the drive shaft from the steering knuckle. Position the drive shaft to the side out of the way.







19. Using mechanic's wire or metal hooks, secure the front shock modules to the frame. DO NOT let the shock modules and steering knuckle hang without supporting them.
20. Reference mark the relationship of the propeller shaft to the front axle pinion yoke.
21. Remove the yoke retainer bolts and yoke retainers from the front axle pinion yoke.
22. Disconnect the propeller shaft from the front axle pinion yoke. Wrap the bearing caps with tape in order to prevent the loss or the bearing rollers.
Secure the propeller shaft to the frame.







23. Remove the transmission oil cooler lines from the retainer.







24. Remove the transmission oil cooler line retaining bracket bolt and bracket.
25. Remove the inner axle shaft.
26. Remove the starter.
27. Remove the Flywheel inspection cover from the left side of the transmission.







28. Remove the battery cable channel bolt from the front of the oil pan.
29. Remove the battery cable channel from the oil pan.
30. Loosen the 2 upper Air Conditioning (A/C) compressor bracket bolts.
31. Remove the 2 lower A/C compressor bracket bolts.







32. Remove the front differential attachment bolts.
33. Secure the front differential to the frame.







34. Remove the 2 lower bellhousing bolts.







35. Remove the oil pan bolts.
36. Remove the oil pan by tilting the rear of the oil pan down to clear the transmission, pull the oil pan rearward past the front wire harness, then lower the oil pan clear of the vehicle.







Important: The oil pan gasket is reusable. It is NOT necessary to remove the oil pan gasket unless damaged.

Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required.

37. Drill out the oil pan gasket retaining rivets (2), if required.
38. Remove the gasket (1) from the pan.
39. Discard the gasket and rivets.
40. Clean and inspect the oil pan.




Installation Procedure







Important: The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane.
If replacing the oil pan gasket it is not necessary to rivet the NEW gasket to the oil pan.

1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.







2. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.







3. Pre-assemble the oil pan gasket and bolts to the pan.
- Install the gasket onto the pan.
- Install the oil pan bolts to the pan and through the gasket.


4. Install the oil pan, oil pan gasket, and bolts to the engine block as an assembly.
5. Hand thread the oil pan bolts into the engine block until snug. Do not tighten at this time.







NOTICE: Refer to Fastener Notice in Service Precautions.



6. Install the 2 lower bellhousing bolts.
6.1. Tighten the lower bellhousing bolts to 50 Nm (37 ft. lbs.).
6.2. Tighten the 2 rear oil pan to rear cover bolts to 12 Nm (106 inch lbs.).
6.3. Tighten the remaining oil pan bolts to 25 Nm (18 ft. lbs.).







7. Release the differential from the frame and install to the oil pan.
8. Install the differential bolts.
Tighten the bolts to 85 Nm (63 ft. lbs.).







9. Install the 2 lower A/C compressor bracket bolts.
10. Tighten the 2 upper A/C compressor bracket bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).

11. Install the battery cable channel to the oil pan.
12. Install the battery cable channel bolt to the oil pan.
Tighten the bolt to 12 Nm (106 inch lbs.).
13. Install the Flywheel inspection cover to the left side of the transmission.
14. Install the starter.
15. Install the inner axle shaft.







16. Install the transmission oil cooler line retaining bracket and bolt.
Tighten the bolt to 9 Nm (80 inch lbs.).







17. Install the transmission oil cooler lines to the retainer.







18. Unsecure the right wheel driveshaft from the frame.
19. install the left and right wheel driveshafts.
20. Unsecure the front shock modules from the frame.







21. Place an adjustable jack stand under the lower control arm.
22. Using the adjustable jack stand raise the lower control arm and knuckle assembly in order to connect the upper ball joint to the upper control arm.
23. Install the upper ball joint pinch nut and bolt.
Tighten the nut to 40 Nm (30 ft. lbs.).

24. Remove the jack stand from under the lower control arm.







25. Connect the sway bar link pins to the lower control arm on both sides.
26. Install the steering gear.
27. Unsecure the propeller shaft from the frame.
28. Align the reference marks on the propeller shaft to the marks on the front axle pinion yoke.
29. Connect the propeller shaft to the front axle pinion yoke.
30. Install the yoke retainers and yoke retainer bolts to the front axle pinion yoke.
Tighten the bolts to 20 Nm (15 ft. lbs.).







31. Install the brake hose retaining bolts to the frame.
Tighten the bolts to 25 Nm (18 ft. lbs.).







32. Connect the wheel speed sensor electrical connectors.







33. Install the left and right ABS wiring harnesses to the retainers.
34. Fill the differential with oil.







35. Install the engine shield and bolts.
Tighten the bolts to 25 Nm (18 ft. lbs.).

36. Install the tires and wheels. Refer to Vehicle Lifting.


37. Fill the engine with oil.
38. Fill the Power Steering System with fluid.







39. Install the front shock upper retaining nuts.
Tighten the nuts to 100 Nm (74 ft. lbs.).

40. Install the oil level indicator tube.
41. Connect the negative battery cable.