GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Engine 🢒 Engine Mechanical - 2.0L (LSJ) 🢒 Oil Pan Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    2. Object Number: 758466 Size: SH
  2. Drain the engine oil.
  3. Remove the engine drive belt. Refer to Drive Belt Replacement .
  4. Remove the intercooler pump bracket bolts from the oil pan.
  5. Remove the lower AC compressor bolt from the oil pan.
  6. Remove the oil pan bolts.

    7. Object Number: 479939 Size: SH
  7. Remove the oil pan.

Installation Procedure

    Object Number: 854301 Size: SH
  1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
  2. Apply a 3.5 mm (0.138 in) bead of RTV around the perimeter of the oil pan and the oil suction port opening. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

    3. Object Number: 479939 Size: SH
  3. Install the oil pan.

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


    Object Number: 466580 Size: SH
  4. Install the oil pan bolts in sequence.

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

  5. Install the AC compressor bolts. Refer to Air Conditioning Compressor Replacement .
  6. Install the intercooler pump bracket bolts.

    7. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  7. Install the engine drive belt. Refer to Drive Belt Replacement .
  8. Lower the vehicle.
  9. Fill the engine oil to the proper level.