GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Prix 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Oil Pan Replacement

Removal Procedure

    Object Number: 911140 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  4. Install the engine support fixture. Refer to Engine Support Fixture .
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  6. Drain the engine oil and remove the oil filter. Refer to Engine Oil and Oil Filter Replacement .
  7. Remove the power steering oil cooler pipe brackets from the frame.
  8. Disconnect the oil level sensor electrical connector (10).
  9. Remove the oil level sensor wiring harness bolt and reposition the oil level sensor wiring harness.

    10. Object Number: 911163 Size: SH
  10. Remove the catalytic converter (3) to the right exhaust manifold pipe stud nuts (2) and reposition the catalytic converter.
  11. Remove the engine mount bracket and the engine mount. Refer to Engine Mount Bracket Replacement - Right Side .
  12. Remove the right and left engine mount strut. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side .
  13. Remove the torque converter covers. Refer to Torque Converter Cover Replacement .
  14. Lower the vehicle.
  15. Using the engine support fixture raise the engine to gain access for the oil pan removal.
  16. Raise the vehicle.

    17. Object Number: 97768 Size: SH

    Notice: Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first.

  17. Remove the oil level sensor.

    18. Object Number: 1646926 Size: SH
  18. Remove the oil pan bolts.
  19. Remove the oil pan.

    20. Object Number: 153599 Size: SH
  20. Remove the oil pump pipe screen assembly and gasket.
  21. Clean the following parts:
    22. • Oil pump screen mating surfaces
    • Oil pan flanges
    • Oil pan rail
    • Front cover
    • Rear main bearing cap
    • Threaded holes

Installation Procedure

    Object Number: 153599 Size: SH
  1. Install the oil pump pipe screen assembly and gasket.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the oil pump pipe screen bolts.

    3. Tighten
    Tighten the bolts to 15 N·m (11 lb ft).

    Notice: Install the oil level sensor, located in the oil pan, after the oil pan is installed. The sensor may be damaged if the oil level sensor is installed first.

  3. Apply a continuous bead 3.0 mm (0.19 in) thick of RTV sealer ensuring that the sealer completely fills the groove in the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  4. To ensure proper sealing, apply additional sealer at the four corners of the block where the front and rear covers meet.

    5. Object Number: 1646926 Size: SH
  5. Install the oil pan.
  6. Clean the oil pan bolts of all debris.
  7. Apply one drop of threadlock to each bolt. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  8. Install the oil pan bolts.

    9. Tighten
    Tighten the oil pan bolts to 14 N·m (125 lb in).


    Object Number: 97768 Size: SH
  9. Install the oil level sensor.

    10. Tighten
    Tighten the sensor to 20 N·m (15 lb ft).

  10. Install the torque converter covers. Refer to Torque Converter Cover Replacement .
  11. Install the engine mount and the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .

    12. Object Number: 911163 Size: SH
  12. Install the catalytic converter (3) to the right exhaust manifold.
  13. Install the catalytic converter pipe stud nuts (2).

    14. Tighten
    Tighten the nuts to 32 N·m (24 lb ft).

  14. Install the oil level sensor wiring harness and the oil level sensor wiring harness bolt to the engine.

    15. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 911140 Size: SH
  15. Connect the oil level sensor electrical connector (10).
  16. Install the power steering oil cooler pipe brackets to the frame.
  17. Install the engine oil filter.
  18. Lower the vehicle.
  19. Remove the engine support fixture.
  20. Install the right and left engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side .
  21. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  22. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  25. Inspect for leaks.