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:

Airbag System Check
The airbag system does not need regularly scheduled maintenance or replacement. Make sure the airbag readiness light is working. See Airbag Readiness Light. Caution If an airbag covering is damaged, opened, or broken, the airbag may not work properly. Do not open or break the airbag coverings. ...

Tires
Every new GM vehicle has high-quality tires made by a leading tire manufacturer. See the warranty manual for information regarding the tire warranty and where to get service. For additional information refer to the tire manufacturer. Warning . Poorly maintained and improperly used tires are ...

Brake Rotor Assembled Lateral Runout Correction
Note: Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. Brake rotor assembled latera ...

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