GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Oil Pan Replacement

Removal Procedure

    Object Number: 758466 Size: SH
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Place a drain pan under the oil pan drain plug.
  3. Remove the oil pan drain plug.
  4. Drain the engine oil.
  5. Remove the engine drive belt. Refer to Drive Belt Replacement .
  6. Remove the lower AC compressor bolt.

    7. Object Number: 1578309 Size: SH
  7. Remove the oil pan bolts (1).

    8. Object Number: 1578310 Size: SH
  8. Remove the oil pan.
  9. Remove any old oil pan sealant (1).

Installation Procedure

    Object Number: 1578310 Size: SH
  1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
  2. Apply a 2 mm (0.079 in) bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm (0.079 in) bead is not required. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  3. Install the oil pan.

    4. Object Number: 1578309 Size: SH
  4. Install the oil pan bolts.

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


    Object Number: 466580 Size: SH
  5. Tighten the oil pan bolts in the sequence shown.

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

  6. Install the lower AC compressor bolt.

    7. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

  7. Ensure that the oil pan drain plug is tightened.

    8. Tighten
    Tighten the drain plug to 25 N·m (18 lb ft).

  8. Install the engine drive belt. Refer to Drive Belt Replacement .
  9. Lower the vehicle.
  10. Fill the crankcase with oil.