Oil Pan: Service and Repair

Removal
1. Disconnect the cable from the battery negative terminal.
2. Remove the air cleaner assembly including the air intake duct.
3. Remove the fan shroud attaching bolts and position the shroud back over the fan.
4. Remove the oil level dipstick.
5. If equipped with a low level oil sensor, remove retainer clip at sensor. Remove electrical connector from sensor.
6. Raise the vehicle.
7. Remove the exhaust manifold to exhaust pipe attaching nuts.
8. Drain the crankcase.
9. Remove the oil filter.
10. Remove the bolts attaching the shift linkage bracket to the transmission bellhousing.
11. Disconnect the transmission cooler lines at the radiator.
12. Remove the four (4) converter cover retaining bolts and remove the cover.
13. Disconnect steering flex coupling. Remove two bolts attaching steering gear to main crossmember and let steering gear rest on the frame away from the oil pan.
14. Remove through bolts attaching the front engine insulator to the chassis.
15. Raise the engine 2-3 inches and insert wood blocks between the engine mounts and the vehicle frame.

NOTE: It may be necessary to raise the engine as much as 5 inches to provide adequate pan-to-crossmember clearance. When raising the engine in one of these vehicles watch the clearance between the transmission dipstick tube and the thermactor downstream air tube. If the tubes contact before adequate pan-to-crossmember clearance is provided, lower the engine and remove the transmission dipstick tube and the downstream air tube. Clamp Cutters and Crimping Tools will be needed to disconnect the tube from the catalyst.

16. Remove the oil pan attaching bolts. Work the oil pan loose and remove.
17. Lower the oil pan onto the crossmember. Remove the oil pick-up tube attaching bolts and the tube support bracket attaching nut. Lower the pick-up tube/screen assembly into the pan and remove the oil pan through the front of the vehicle.
18. Remove the oil pan seal from the main bearing cap. Discard the seal.

Installation

NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

1. Clean the gasket surfaces on the cylinder block, oil pan, and oil pick-up tube.
2. Trial fit the oil pan to the cylinder block. Make sure enough clearance has been provided to allow the oil pan to be installed without the sealant being scraped off when the pan is positioned under the engine.
3. Remove the oil pan.
4. Install the oil pan gasket as follows:
a. Apply a thin film of G.E. Pressure-Sensitive Adhesive PSA 6574 or equivalent to block rails front cover, rear bearing cap and block side of gasket.

NOTE: The gasket taps go to the block side.

WARNING: Use adequate ventilation when applying adhesive.

b. Allow adhesive to become tacky, then apply a 3-4 mm (approximately 1/8 inch) bead of Silicone Rubber or equivalent to joints between front cover and block.
c. Apply a 4-5 mm (approximately 1/7 inch) bead of Silicone Rubber or equivalent into the groove where main bearing cap meets block.
d. Immediately position oil pan gasket against engine block and press into position, being careful to press out the sealant beads applied in Step c.
5. Install the oil pan as follows:
a. Place oil pickup tube/screen assembly in the oil pan.
b. Position oil pan.
c. Position oil pickup tube/screen with a new gasket. Install tube attaching bolts and support bracket attaching nut. Tighten attaching bolt to 20-30 Nm (15-22 ft-lbs) and support bracket nut to 40-55 Nm (30-40 ft-lbs).
d. Install left and right side oil pan reinforcements and retaining bolts. Tighten pan bolts to 9-12 Nm (80-105 in-lbs).
6. Raise the engine, remove the blocks of wood supporting the engine, and lower the engine into position.
7. Install the front mount and damper (if equipped) attaching bolts and nuts.
8. Position the steering gear to the main crossmember. Install the two attaching bolts and connect the steering flex coupling.
9. Position the shift linkage bracket and install the attaching bolts.
10. Connect the transmission oil cooler lines.
11. Install a new oil filter.
12. Install the transmission dipstick tube and the thermactor downstream air tube (if removed). Clamp Cutters and Crimping Tools will be needed to connect the air tube to the catalyst.
13. Lower the vehicle.
14. Position the vacuum solenoids on dash panel and install the attaching screws.
15. Position the fan shroud on the radiator and install the attaching bolts.
16. Connect the battery cable.
17. Fill the crankcase to the correct level with the specified oil.
18. Start the engine and check the fluid levels in the transmission. Check for engine oil, and transmission fluid leaks.
19. Install the air cleaner assembly including air intake duct.