Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Oil Pan Installation

Special Tools

EN-49980 Guidance Pins

For equivalent regional tools, refer to Special Tools.

  1. Clean the sealing surfaces from old sealing material, dirt, oil and grease.

  2. Note:

    The sealing bead should be applied close to the inner edge of the oil pan. Take care that the oil suction gallery (4) will not get contaminated with sealing compound or dirt. The thickness of the sealing bead (3) should be 2 mm (0.0787 in).

  3. Apply sealing compound to the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers.
  4. Apply sealing compound to the groove of the engine front cover (1). Refer to  Adhesives, Fluids, Lubricants, and Sealers.
  5. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate.

  6. Note:

    The complete installation procedure of the oil pan should not take longer than 10 minutes.

  7. Install the 2  EN-49980 pins (1) and (2) to the shown oil pan screw bores.


  8. Caution:

    Use care when installing the oil pan to prevent disruption of the sealing bead. The sealing bead should remain consistent until the oil pan is mated with the engine. An inconsistent sealing bead can cause an insufficient seal and result in engine damage.

  9. Carefully install the oil pan. Guide the oil pan with EN-49980 pins (2) and the equivalent screw bores (1).
  10. Hold the oil pan with 4 oil pan bolts.
  11. Remove EN-49980 pins.
  12. Install the remaining 12 oil pan bolts and hand tighten.

  13. Lay a straight edge (1) against the oil pan and engine block. Using a rubber mallet, adjust the transition in area (2) until there is no clearance between oil pan and the straight edge.
  14. Caution:

    Refer to Fastener Caution.

  15. Tighten the 16 oil pan bolts to  10 Y (89 lb in)

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Oil Pan Cleaning and Inspection
Warning: Wear safety glasses when using compressed air in order to prevent eye injury. Caution: To ensure proper engine lubrication, clean clogged or contaminated oil ga ...

Oil Pan Removal
Remove the 16 oil pan bolts (1). Caution: Pry the oil pan carefully in order to prevent damage to the transaxle case or the oil pan sealing surfaces. Place a ...

Other materials:

Protecting Exterior Bright Metal Moldings
Caution Failure to clean and protect the bright metal moldings can result in a hazy white finish or pitting. This damage would not be covered by the vehicle warranty. The bright metal moldings on the vehicle are aluminum. To prevent damage always follow these cleaning instructions: Be sure ...

Tire and Wheel Assembly-to-Hub/Axle Flange Match-Mounting
Note: After remounting a tire and wheel assembly to a hub/axle flange, remeasure the tire and wheel assembly on-vehicle runout in order to verify that the amount of runout has been reduced and brought to within tolerances. Mark the location of the high spot on the tire and wheel asse ...

New Vehicle Break-In
Notice: The vehicle does not need an elaborate break-in. But it will perform better in the long run if you follow these guidelines: Do not drive at any one constant speed, fast or slow, for the first 805 km (500 mi). Do not make full-throttle starts. Avoid downshifting t ...

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