Special Tools

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Carefully disconnect the throttle body air inlet duct.
3. Remove the engine mount struts from the engine. Refer to Engine Mount Strut Replacement and Engine Mount Strut Replacement.
4. Remove the drive belt. Refer to Drive Belt Replacement.
5. Install the J 28467-B , the J 28467-90A , and the J 36462-A . Refer to Engine Support Fixture.
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Disconnect the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
8. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
9. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
10. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.



11. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
12. Remove the AC compressor bracket bolts. Reposition and secure the AC compressor.
13. Disconnect the power steering oil cooler pipe brackets from the frame.
14. Remove the engine mount bracket bolts from the engine. Refer to Engine Mount Bracket Replacement.
15. Remove the engine mount lower nuts.
16. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
17. Disconnect the oil level sensor wiring harness connector. Refer to Engine Oil Level Indicator Switch Replacement in Engine Controls - 3.8L.

Notice: Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first.




18. Remove the oil level sensor. Refer to Engine Oil Level Indicator Switch Replacement in Engine Controls - 3.8L.
19. Lower the vehicle.
20. Use the engine support fixture in order to raise the engine. Refer to Engine Support Fixture.
21. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
22. Suitably support the frame. Loosen the left side frame bolts. Remove the right side frame bolts. Lower the frame for access.
23. Remove the engine mount and the engine mount bracket.



24. Remove the oil pan retaining bolts.
25. Lower the oil pan.
26. Remove the oil pan.



27. Remove the oil pump pipe and screen assembly and the oil pan gasket.
28. Clean the following parts:

•	The oil pan flanges

•	The oil pan rail

•	The front cover

•	The rear main bearing cap

•	The threaded holes

1. Apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the topside of the new gasket. Apply the RTV sealant directly over the gaskets sealing bead.
2. Install the NEW oil pan gasket onto the engine.



3. Apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the bottom side of the new gasket. Apply the RTV sealant directly over the gaskets sealing bead.

Notice: Install the oil level sensor, located in the oil pan, after the oil pan is installed. The sensor may be damaged if the oil level sensor is installed first.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Install the oil pan gasket and the oil pump pipe and screen assembly.

Tighten
Tighten the oil pump pipe and screen bolts to 15 N·m (11 lb ft).




5. Install the oil pan.
6. Clean the oil pan bolts and apply one drop of thread lock compound GM P/N 12345382 or equivalent to the oil pan bolt threads.

Important: Do not overtighten bolts or damage to the oil pan may occur, resulting in an oil leak.

7. Install the oil pan bolts.

Tighten
Tighten the oil pan bolts to 14 N·m (125 lb in).

8. Position the engine mount and the engine mount bracket to the proper position. Install the engine mount bracket bolts to the engine. Refer to Engine Mount Bracket Replacement.
9. Install new right side frame bolts. Make sure the frame is suitably supported. Install new left side frame bolts. Refer to Frame Removal in Frame and Underbody.
10. Lower the vehicle.
11. Use the J 28467-B in order to lower the engine. Refer to Engine Support Fixture.
12. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Install the engine mount lower nuts.

Tighten
Tighten the engine mount lower nuts to 47 N·m (35 lb ft).




14. Install the oil level sensor. Refer to Engine Oil Level Indicator Switch Replacement in Engine Controls - 3.8L.

Tighten
Tighten the oil level sensor to 20 N·m (15 lb ft).

15. Connect the oil level sensor wiring harness connector. Refer to Engine Oil Level Indicator Switch Replacement in Engine Controls - 3.8L.
16. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
17. Connect the power steering oil cooler pipe brackets to the frame.
18. Install the AC compressor bracket bolts. Refer to Compressor Replacement (3.8L) in HVAC.



19. Install the new oil filter. Refer to Engine Oil and Oil Filter Replacement.
20. Install the oil pan bolt. Refer to Engine Oil and Oil Filter Replacement.
21. Install the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
22. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
23. Connect the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
24. Lower the vehicle.
25. Remove the J 28467-B , the J 28467-90A , and the J 36462-A .
26. Install the drive belt. Refer to Drive Belt Replacement.
27. Install the engine mount struts to the engine. Refer to Engine Mount Strut Replacement and Engine Mount Strut Replacement.
28. Carefully install the throttle body air inlet duct.
29. Fill the crankcase with new engine oil. Refer to Engine Oil and Oil Filter Replacement.
30. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
31. Inspect for the proper fluid levels.
32. Inspect for leaks.
33. Measure the wheel alignment. Refer to Wheel Alignment Specifications in Wheel Alignment.