GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 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 Replacement .
  12. Remove the torque converter covers. Refer to Torque Converter Cover Replacement for the 4T65 E automatic transmission.
  13. Lower the vehicle.
  14. Using the engine support fixture raise the engine to gain access for the oil pan removal.
  15. Raise the vehicle.

    16. 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.


    Object Number: 97768 Size: SH
  16. Remove the oil level sensor.

    17. Object Number: 97771 Size: SH
  17. Remove the oil pan bolts.
  18. Remove the oil pan.

    19. Object Number: 97769 Size: SH
  19. Remove the oil pump pipe screen assembly and the oil pan gasket.
  20. Clean the following parts:
    21. • Oil pump screen mating surfaces
    • Oil pan flanges
    • Oil pan rail
    • Front cover
    • Rear main bearing cap
    • Threaded holes

Installation Procedure

    Object Number: 97769 Size: SH
  1. Install the oil pump pipe screen assembly.

    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).


    Object Number: 1341869 Size: SH

    Important: For aluminum oil pans, begin with step 6. For steel oil pans, skip steps 6 and 7.

  3. For steel oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the topside of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead.
  4. Install the NEW windage tray gasket onto the engine.

    5. Object Number: 741054 Size: SH
  5. Apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the bottom side of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead.

    6. Object Number: 1572701 Size: SH
  6. For aluminum oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148), ensuring that the sealer also completely fills the groove in the oil pan.
  7. To ensure proper sealing, apply additional sealer at the four points called out in the illustration (1).

    8. Object Number: 44775 Size: SH
  8. Install the oil pan and oil pan windage tray gasket, if applicable.
  9. Clean the oil pan bolts of all debris.
  10. Apply one drop of GM P/N 12345382 (Canadian P/N 10953489) to each bolt.
  11. Install the oil pan bolts.

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


    Object Number: 97768 Size: SH

    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.

  12. Install the oil level sensor.

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

  13. Install the torque converter covers. Refer to Torque Converter Cover Replacement for the 4T65 E automatic transmission.
  14. Install the engine mount and the engine mount bracket. Refer to Engine Mount Replacement .

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

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

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

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


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