Oil Pan Replacement

REMOVAL

Note: The Saturn LS L81 uses RTV to seal oil pan to engine block not a gasket as shown in typical oil pan representation.





1. Remove nose cone bracket bolts from oil pan.
2. Remove lower transmission flange to oil pan bolts.

3. Remove oil pan bolts.

IMPORTANT: When removing oil pan, use only sedinated pry points to prevent damage to sealing flange. RTV cutter tool SA9123 may be used to brake the oil pan loose from the engine block.

4. Use pry point to brake loose the seal. Bump the pan with a rubber mallet to loosen the pan from the engine block.
5. Remove oil pan.

INSTALLATION

IMPORTANT: Alignment of the oil pan is critical to ensure transaxle nose cone-to-oil pan and transaxle mating flange-to-oil pan alignment. Application of RTV is critical to ensure positive seal of the chamfered sealing flange on the oil pan-to-engine block mating surface. After pan has been placed on the engine block, it may not be moved as this will not allow the sealant to function properly in the chamfered flange.

1. Clean oil pan and engine block sealing flanges with a chlorinated solvent such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432 (or equivalent).
2. Apply a 2 mm bead of Loctite (R) 5900 (or equivalent) 3 mm from the inside edge of the oil pan.

IMPORTANT: If the repair is being performed out of vehicle, attach the transaxle nose cone bracket to engine block and use strait edge at the transaxle-to-engine mating flange for positive oil pan alignment to the engine block.





3. Assemble oil pan to engine block.
a. Use the transaxle nose cone as guide for fore/aft alignment.
b. Use the transaxle-to-engine block (or straight edge if transaxle is removed) as left/right alignment.
c. Install nose cone bracket-to-oil pan bolts and tighten finger the in order align fore/aft position.
d. Install transaxle-to-oil pan bolts and tighten finger tight in order to align right/left position. (If transaxle is not installed, use straight edge for alignment.)
e. Install oil pan bolts, use thread locking compound threadlocker Loctite (R) 242 or equivalent.


CAUTION
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed.
Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended and described are effective methods of performing service and repair. Some of these procedures require the use of tools specifically designed for the purpose.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool that is not recommended by the vehicle manufacturer must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure, or tool selected.
It is important to note that this manual contains various "Cautions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these "Cautions" and "Notices" are not exhaustive; it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.
This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to "Service Precautions" and the SIR Component and Wiring Location views in the "SIR Service Manual" before performing service on or around SIR components or wiring. Failure to follow "Service Precautions" could result in possible air bag deployment, personal injury, otherwise unneeded SIR system repairs.
To help avoid accidental air bag deployment and personal injury, when servicing a vehicle that requires repair of the SIR system and another vehicle system, it is recommended that the SIR be repaired first using service manual procedures.

CAUTION
Saturn Service Manuals are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not to operate.

NOTICE
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application.
The application service procedure will identify, where necessary, those fasteners that must be replaced after removal; or those fasteners that require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener.
When you install fasteners, use the correct tightening sequence and specifications.
Following these instructions can help you avoid damage to parts and systems.
All information, illustrations and specifications contained in this guide are based on the latest product information that was available at the time of publication. Saturn reserves the right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any form or by any means, including but not limited to electronic, mechanical photocopying, recording or otherwise, without the prior written permission of the Saturn Corporation. This includes all text. illustrations. tables and charts.