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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1019 (Engine Mechanical - 4.8L, 5.3L & 6.0L (Repair Instructions - 1 Of 3)) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Oil Pan Replacement >> Installation Procedure

Installation Procedure

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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.
  • Do not reuse the oil pan gasket.
  • It is not necessary to rivet the NEW gasket to the oil pan.
  1. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 in) 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. Fig 1: View Of Sealant Applied To Front Oil Pan-To-Engine Block Junction
    GM451897Courtesy of GENERAL MOTORS CORP.
  2. Apply a 5 mm (0.20 in) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 in) 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. Fig 2: View Of Sealant Applied To Rear Oil Pan-To-Engine Block Junction
    GM451898Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket.
  3. Pre-assemble the oil pan gasket 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, gasket and bolts to the engine block.
    5. Fig 3: View Of Oil Pan & Bolts
    GM683355Courtesy of GENERAL MOTORS CORP.
  5. Tighten the oil pan bolts until snug. Do not overtighten.
  6. Install the two bottom bellhousing bolts until snug, if equipped with a manual transmission.
    7. Fig 4: View Of Transmission Mounting Bolts (Manual Transmission)
    GM394442Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission.
    8. Fig 5: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  8. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission.
    9. Fig 6: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the bottom bolt on the left side until snug.

    Tighten: 

    1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 N.m (18 lb ft).
    2. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in).
    3. Tighten the bellhousing, converter cover, and transmission bolts/stud to 50 N.m (37 lb ft).

    10. Fig 7: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  10. Install the positive battery cable clip and bolt to the oil pan.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    11. Fig 8: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  11. Install the engine oil cooler lines to the positive battery cable clip.
  12. Install the following to the positive battery cable clip:
    • Engine wiring harness clip
    • Positive battery cable clip
    13. Fig 9: View Of Engine Wiring Harness Clip & Positive Battery Cable Clip
    GM1236367Courtesy of GENERAL MOTORS CORP.
  13. Slide the channel pin in to the oil pan tab.
  14. Install the battery cable channel bolt.

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

    15. Fig 10: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  15. Connect the oil level sensor electrical connector (3).
    16. Fig 11: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  16. Install the transmission cover and bolt.

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

    17. Fig 12: View Of Transmission Cover & Bolt
    GM832978Courtesy of GENERAL MOTORS CORP.
  17. Install the crossbar.
  18. Install the crossbar bolts.

    Tighten:  Tighten the bolts to 100 N.m (74 lb ft).

    19. Fig 13: View Of Crossbar Bolts & Bar (2WD)
    GM328107Courtesy of GENERAL MOTORS CORP.
  19. If equipped, install the oil pan skid plate.
  20. Install the oil pan skid plate bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    21. Fig 14: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  21. Install the transmission cover bolts

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

    22. Fig 15: View Of Transmission Cover Bolt
    GM663487Courtesy of GENERAL MOTORS CORP.
  22. Raise the front drive axle into position.
  23. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time.
    24. Fig 16: View Of Differential Carrier Upper Mounting Bolt
    GM834276Courtesy of GENERAL MOTORS CORP.
  24. If equipped with 4WD, instal the differential carrier lower mounting bolt and nut.

    Tighten:  Tighten the bolts to 100 N.m (75 lb ft).

    25. Fig 17: View Of Differential Carrier Lower Mounting Bolt
    GM834278Courtesy of GENERAL MOTORS CORP.
  25. If equipped with 4WD, install the inner axle housing washers and nuts to the bracket.

    Tighten:  Tighten the nuts to 100 N.m (75 lb ft).

    26. Fig 18: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  26. Remove the jack from the front drive axle.
  27. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement .
  28. If equipped with RPO HP2, refill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
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