LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 421 (Engine Mechanical - 4.8L, 5.3L, & 6.0L (On-Vehicle)) >> Repair Instructions >> Oil Pan Replacement >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
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.
    Fig 1: View Of Sealant Applied To Front Oil Pan-To-Engine Block Junction
    GM451897Courtesy of GENERAL MOTORS CORP.
  1. Apply a 5 mm (0.20 in) bead of sealant GM P/N United states 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 2: View Of Sealant Applied To Rear Oil Pan-To-Engine Block Junction
    GM451898Courtesy of GENERAL MOTORS CORP.
  2. Apply a 5 mm (0.20 in) bead of sealant GM P/N United States 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 3: Oil Pan & Bolts
    GM683355Courtesy 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. Tighten the oil pan bolts until snug. Do not overtighten.
    6. Fig 4: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  6. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission.
    7. Fig 5: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission.
    8. Fig 6: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  8. Install the bottom bolt on the left side until snug.

    Tighten: 

    1. Tighten the oil pan-to-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 converter cover, and transmission bolts/stud to 50 N.m (37 lb ft).

    9. Fig 7: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  9. Install the positive battery cable clip and bolt to the oil pan.

    Tighten:  Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).

    10. Fig 8: View Of Positive Battery Cable, Channel & Bolt
    GM662508Courtesy of GENERAL MOTORS CORP.
  10. Slide the channel pin in to the oil pan tab.
  11. Install the battery cable channel bolt.

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

    12. Fig 9: Identifying Electrical Connector (Right Side Of Engine)
    GM662991Courtesy of GENERAL MOTORS CORP.
  12. Connect the oil level sensor electrical connector (6).
    13. Fig 10: View Of Left Closeout Cover & Bolt
    GM178477Courtesy of GENERAL MOTORS CORP.
  13. Install the transmission cover and bolt.

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

    14. Fig 11: View Of Crossbar Bolts & Bar (2WD)
    GM328107Courtesy of GENERAL MOTORS CORP.
  14. Install the crossbar.
  15. Install the crossbar bolts.

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

    16. Fig 12: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  16. If equipped, install the oil pan skid plate.
  17. Install the oil pan skid plate bolts.

    Tighten:  Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).

    18. Fig 13: View Of Transmission Cover Bolt
    GM663487Courtesy of GENERAL MOTORS CORP.
  18. Install the transmission cover bolt.

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

    19. Fig 14: View Of Differential Carrier Upper Mounting Bolt
    GM834276Courtesy of GENERAL MOTORS CORP.
  19. Raise the front drive axle into position.
  20. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time.
    21. Fig 15: View Of Differential Carrier Lower Mounting Bolt
    GM834278Courtesy of GENERAL MOTORS CORP.
  21. If equipped, with 4WD, install the differential carrier lower mounting bolt and nut.

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

    22. Fig 16: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  22. If equipped with 4WD, install the inner axle housing nuts and washers to the bracket.

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

  23. Remove the front drive axle support.
  24. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement .
scientia non olet · About LEMON Manuals