GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Engine 🢒 Engine Mechanical - 1.8L (2H0) 🢒 Oil Pan Replacement

Removal Procedure
  1. Open the hood.

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the battery.
  3. Raise the vehicle by its full height.
  4. Place a drip pan underneath.
  5. Drain the engine oil.
    6. • Remove the oil drain bolt.
    • Collect the engine oil.

    Notice: Refer to Fastener Notice in the Preface section.

  6. Tighten the oil drain bolt.

    7. Tighten
    Tighten the bolt to 14 N·m (124 lb in).

  7. Replace the seal ring.
  8. Lower the vehicle by its full height.
  9. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
  10. Raise the vehicle by its full height.
  11. Remove the lower engine cover and the right engine splash guard.

    12. Object Number: 1936899 Size: SH
  12. Expose the catalytic converter control oxygen sensor wiring harness (1).
    13. • Disconnect the wiring harness (2).
    • Disconnect the wiring harness connector (3).
  13. Release the exhaust gas system.

    14. Remove the 4 rubber dampers from the bracket.


    Object Number: 1946674 Size: SH
  14. Remove the front exhaust pipe (2) from the catalytic converter (1).

    15. Remove the 3 nuts (3).

  15. Take out the exhaust system.

    16. Remove the 6 damper rings.

  16. Disconnect the oil level sensor wiring harness plug.

    17. Object Number: 1945955 Size: MH
  17. Loosen the oil pan.
    18. • Remove the 3 bolts (arrows) from the transmission.
    • Remove the 13 bolts (arrows) from the engine block.
  18. Remove the oil pan evenly all the way around with a suitable tool.

Installation Procedure
  1. Clean the sealing surfaces.

    2. Object Number: 1944491 Size: SH
  2. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant to the joints (arrows).

    3. Object Number: 1944480 Size: MF

    Important: The assembly time including torque check must take no longer than 10 minutes.

  3. Apply the oil pan sealant to the oil pan.

    4. Apply an approximately 3.5 mm thick bead of oil pan sealant (1) as illustrated.

    Notice: Refer to Fastener Notice in the Preface section.

  4. Install the oil pan.

    5. Tighten

        • Tighten the 13 bolts on the cylinder block to 10 N·m (89 lb in).
        • Tighten the 3 bolts on the transmission to 40 N·m (30 lb ft).
  5. Connect the engine oil level wiring harness plug.
  6. Install the front exhaust pipe to the catalytic converter.
    7. • Insert the new gasket.
    • Tighten 3 new nuts.

    Tighten
    Tighten the new nuts to 20 N·m (15 lb ft).

    • Attach the 4 rubber dampers.
  7. Install the lower engine cover and the right engine splash guard.
  8. Lower the vehicle by its full height.
  9. Install the oil dipstick guide tube. Refer to Oil Level Indicator and Tube Replacement
  10. Top up the engine oil.

    11. Inspect the engine oil level and correct if necessary.

  11. Connect the battery.
  12. For programming procedures, refer to Control Module References .
  13. Close the hood.