Chevrolet Sonic Repair Manual: Oil Pan Installation

Chevrolet Sonic Repair Manual / Powertrain / Engine / Engine Lubrication / Oil Sump/Pan / Oil Pan Installation

Special Tools

EN-49980 Guidance Pins

For equivalent regional tools, refer to Special Tools.

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

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).

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

Note:

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

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

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.

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

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.

Caution:

Refer to Fastener Caution.

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

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:

Engine Block Cleaning and Inspection
Special Tools EN-8087 Cylinder Gauge For equivalent regional tools, refer to Special Tools. Clean the sealing material from the gasket mating surfaces (2). Clean the engine block (1) and lower crankcase in a cleaning tank with solvent appropriate for aluminum. Refer ...

Fuel Tank Heat Shield Replacement
Removal Procedure Support the fuel tank with a suitable jack. Remove the fuel tank strap fasteners (1) and lower the fuel tank straps (2). Remove the fuel tank heat shield fasteners (1) and remove the fuel tank heat shield (2). ...

Clutch Pedal Position Sensor Replacement
Removal Procedure Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement. Remove the clutch pedal position sensor bolt (2). Remove the clutch pedal position sensor (1). Disconnect the clu ...

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