GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2009 🢒 G8 🢒 Engine 🢒 Engine Mechanical - 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L 🢒 Oil Pan Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.

  1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.

    2. Warning: Refer to Safety Glasses Warning in the Preface section.

    Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  3. Remove the air deflector. Refer to Front Air Deflector Replacement.
  4. Drain the engine oil and remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
  5. Remove the engine splash shield. Refer to Engine Splash Shield Replacement.
  6. Remove the starter motor. Refer to Starter Motor Replacement.

    7. Object Number: 1954101 Size: SH
  7. Remove the left side close out cover to cylinder block retaining bolt (2).
  8. Remove the left side close out cover (1).

    9. Object Number: 1954100 Size: SH
  9. Remove the right side close out cover to cylinder block retaining bolt (2).
  10. Remove the right side close out cover (1).

    11. Object Number: 1961761 Size: SH

    Note: Observing the orientation of the intermediate steering shaft (1) with reference to the pinion shaft (3) will minimize the potential of incorrect steering column assembly alignment.

  11. Mark the intermediate steering shaft (1) in relation to the pinion shaft (3).

    12. Note: Secure the steering wheel to prevent rotation otherwise damage to the SIR coil will occur.

    Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.

  12. Remove the intermediate steering shaft to pinion shaft retaining bolt (2) and discard.

    13. Discard the bolt.

  13. Disconnect the intermediate shaft (2) from the pinion shaft (3).

    14. Object Number: 1958071 Size: SH
  14. Remove the steering gear to sub-frame retaining bolts (1).
  15. Slide the steering gear forward to gain full access to the sump.

    16. Object Number: 1954097 Size: SH
  16. Disconnect the oil level/temperature sensor electrical connector (1) from the oil level/temperature sensor.

    17. Object Number: 1954102 Size: SH
  17. Remove the transmission to oil pan retaining bolts (1).

    18. Object Number: 1954098 Size: SH
  18. Remove the oil pan to front cover retaining bolts (1).
  19. Remove the oil pan to cylinder block front retaining bolts (2).
  20. Lower the vehicle.

    21. Object Number: 1943716 Size: SH
  21. Position the J 41798 (1) on the cylinder head (3).

    22. Caution: Refer to Fastener Caution in the Preface section.

  22. Install the J 41798 to cylinder head retaining bolts (2) and tighten to 50 N·m (36 lb ft).

    23. Note: When lifting the engine assembly, observe the clearance between the rear of the engine assembly and the dash panel.

  23. Install J 41803 J-41803 and  J 28467-B and raise the engine assembly 20 mm.
  24. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

    25. Object Number: 1943694 Size: SH
  25. Remove the lower engine mount to crossmember retaining nut (1) from both engine mounts.

    26. Object Number: 1954099 Size: SH
  26. Remove the oil pan to engine rear cover retaining bolts (2).
  27. Remove the oil pan to cylinder block retaining bolts (1).
  28. Remove the oil pan (3).

    29. Object Number: 1954106 Size: SH

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

    Note: Take care not to gouge, score, or damage the oil pan sealing surface.

  29. Drill out the retaining rivets (3) from the oil pan, if required.

    30. Note: The oil pan gasket and rivets are single use only components and must be replaced whenever the oil pan is removed from the cylinder block.

  30. Remove the oil pan gasket (1) from the oil pan (2).

    31. Discard the gasket and rivets.

  31. Clean and inspect the oil pan as necessary. Refer to Oil Pan Cleaning and Inspection.

    32. .

  32. Clean the base of the engine block. Refer to Replacing Engine Gaskets.

    33. .

Installation Procedure

    Note: The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission housing. 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 are flush. The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing plane.

    Note: The original oil pan gasket is retained and aligned to the oil pan by rivets. When installing a new gasket, it is not necessary to install new oil pan gasket rivets.

    It is not necessary to rivet the NEW gasket to the oil pan.


    Object Number: 1954103 Size: SH
  1. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block (1). Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    2. Object Number: 1954105 Size: SH
  2. Apply a 5 mm (0.2 in) bead of sealant 20 mm (0.8 in) long to the engine block (1). Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    3. Object Number: 1954108 Size: SH

    Note: Make sure to align the oil gallery passages in the oil pan and engine block correctly, with the oil pan gasket.

  3. Preassemble the oil pan gasket (2) to the oil pan (3).
    4. 3.1. Install the oil pan gasket (2) to the oil pan (3).
    3.2. Install the oil pan retaining bolts (1) to the oil pan (3) and through the oil pan gasket (2).

    Object Number: 1954099 Size: SH
  4. Install the oil pan assembly (3).
  5. Install the oil pan to cylinder block retaining bolts (1) finger tight. Do not over tighten.
  6. Install the oil pan to engine rear cover retaining bolts (2) finger tight. Do not over tighten.
  7. Lower the vehicle.
  8. Lower the engine to engage the engine mounts to the front sub-frame.

    9. Object Number: 1943694 Size: SH
  9. Raise the vehicle.

    10. Caution: Refer to Fastener Caution in the Preface section.

  10. Install the lower engine mount to front sub-frame retaining nuts (1) on both engine mounts and tighten to 80 N·m (59 lb ft).
  11. Lower the vehicle.
  12. Remove J 41803 and J 28467-B from the engine.

    13. Object Number: 1943716 Size: SH
  13. Remove the J 41798 to cylinder head retaining bolts (2).
  14. Remove the J 41798  (1) from the cylinder head (3).

    15. Object Number: 1954098 Size: SH
  15. Install the oil pan to front cover retaining bolts (1) finger tight. Do not over tighten.
  16. Install the oil pan to cylinder block retaining bolts (2) finger tight. Do not over tighten.
  17. Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces.
  18. Align the oil pan until the rear of engine block and the rear of oil pan are flush or even.
  19. Measure the oil pan-to-engine block alignment.
    20. 19.1. Place a straight edge across the rear of the engine block and rear of the oil pan at the transmission housing mounting surfaces.

            Note: The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing mounting surfaces.

    19.2. Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface and check to make sure that there is no more than a 0.25 mm (0.01 in) gap between the pan and the straight edge.
    19.3. If the oil pan alignment is not within specifications, remove the oil pan and repeat procedures 17-19.

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1954109 Size: SH
  20. Tighten the oil pan to cylinder block retaining bolts (1) to 25 N·m (18 lb ft).
  21. Tighten the oil pan to engine rear oil seal housing retaining bolts (2) to 12 N·m (106 lb in).

    22. Object Number: 1954098 Size: SH
  22. Tighten the oil pan to cylinder block retaining bolts (2) to 25 N·m (18 lb ft).
  23. Tighten the oil pan to front cover retaining bolts (1) to 25 N·m (18 lb ft).
  24. Position the steering gear in the correct location.

    25. Object Number: 1958071 Size: SH
  25. Install the steering gear to sub-frame retaining bolts (1) and tighten to 65 N·m (48 lb ft).

    26. Object Number: 1961761 Size: SH

    Note: The intermediate steering shaft and pinion shaft splines must be installed in the position recorded during removal and aligned with the marks previously made.

  26. Connect the intermediate steering shaft (1) to the pinion shaft (3).
  27. Install the intermediate steering shaft to pinion shaft NEW retaining bolt (2) and tighten to 25 N·m (18 lb ft).

    28. Object Number: 1954100 Size: SH
  28. Install the right side close out cover (1).
  29. Install the right side close out cover to cylinder block retaining bolt (2) and tighten to 12 N·m (106 lb in).

    30. Object Number: 1954101 Size: SH
  30. Install the left side close out cover (1).
  31. Install the left side close out cover to cylinder block retaining bolt (2) and tighten to 12 N·m (106 lb in).

    32. Object Number: 1954097 Size: SH
  32. Connect the oil level/temperature sensor electrical connector (1) to the oil level/temperature sensor.
  33. Install the starter motor. Refer to Starter Motor Replacement.
  34. Install the air deflector. Refer to Front Air Deflector Replacement.
  35. Install the engine splash shield. Refer to Engine Splash Shield Replacement.
  36. Lower the vehicle to the ground
  37. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
  38. Replace the engine oil and oil filter. Refer to Engine Oil and Oil Filter Replacement.