GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Malibu 🢒 Engine 🢒 Engine Cooling 🢒 Oil Pan Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the crankcase.
  4. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  5. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  6. Remove the right front antilock brake system (ABS) wheel speed sensor harness from the right suspension support.
  7. Remove the right front ball joint, the cotter pin, and the nut. Separate the ball joint from the control arm. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  8. Remove lower closeout panel.

    9. Object Number: 63664 Size: SH
  9. Remove the A/C compressor bolts and position the compressor aside.
  10. Remove engine to transmission brace.
  11. Disconnect oil level sensor.
  12. Remove brake line from frame retainers.
  13. Remove transmission mount nuts and bolts.
  14. Loosen left side cradle bolts.
  15. Remove the right front and the right rear engine cradle bolts.
  16. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    17. Object Number: 54394 Size: SH
  17. Remove the oil pan side bolts.
  18. Remove the oil pan bolts.
  19. Remove the oil pan.
  20. Remove the oil pan gasket.
  21. Clean the following items:
    22. • The oil pan flanges
    • The oil pan rail
    • The front cover
    • The rear main bearing cap
    • The threaded holes

Installation Procedure

    Object Number: 54394 Size: SH
  1. Install a new gasket. Place sealant on the oil pan gasket tabs if you are installing the rear main bearing cap. Place the sealer on the tabs that insert into the gasket groove of the outer surface on the main bearing cap. Use GM P/N 1052080 or the equivalent.
  2. Install the oil pan.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the oil pan bolts.

    4. Tighten
    Tighten the oil pan bolts to 25 N·m (18 lb ft).

  4. Install the oil pan (side) bolts.

    5. Tighten
    Tighten the oil pan (side) bolts to 50 N·m (37 lb ft).

  5. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  6. Install the flywheel inspection cover.

    7. Object Number: 63663 Size: SH
  7. Install the A/C compressor to the engine. Refer to Air Conditioning Compressor Replacement in HVAC Systems.
  8. Install the frame bolts on the right side.

    9. Tighten
    Tighten frame bolts to 191 N·m (141 lb ft).

  9. Install transmission mount bolts/nuts.

    10. Tighten
    Tighten bolts/nuts to 130 N·m (96 lb ft).

  10. Install the right side ball joint. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  11. Connect the right front antilock brake system (ABS) wheel speed sensor harness.
  12. Install brake line to frame retainers.
  13. Install engine to transmission brace.
  14. Install the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  15. Install the right front tire and wheel assembly.
  16. Install lower closeout panel.
  17. Lower the vehicle.
  18. Fill the crankcase.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.