Chevrolet Chevette/1000 1976-1988 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



Gasoline Engine


Click image to see an enlarged view

Fig. Fig. 1Exploded view of the oil pan for gasoline engines

TURBO HYDRA-MATIC 180 AUTOMATIC AND MANUAL TRANSMISSION

A special lifting tool is necessary for this procedure. This tool can be fabricated from channel iron; pattern it after the tool shown in the illustration.

  1. Remove the heater housing assembly from the firewall and rest it on top of the engine.
  2.  
  3. Drain the cooling system.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove upper radiator support. On air conditioning equipped vehicles, remove the upper half of the fan shroud.
  2.  
  3. Remove radiator hoses and radiator.
  4.  

If equipped with an automatic transmission, disconnect the cooler lines from the radiator.

  1. If equipped with air conditioning, remove the condenser to radiator support attaching nuts and remove condenser from support. Lay it on top of the engine.
  2.  
  3. Remove the engine mount retaining nuts and clips.
  4.  
  5. Disconnect the fuel line from the charcoal canister.
  6.  
  7. Raise the vehicle and drain the engine oil.
  8.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the exhaust pipe bolts at the manifold.
  2.  
  3. Remove the body to cross member braces.
  4.  
  5. On manual transmission equipped vehicles, remove the rack and pinion-to-front crossmember attaching bolts. Pull the unit down and out of the way.
  6.  
  7. Remove the stabilizer from the body.
  8.  
  9. Install tool J-26436 and raise the engine.
  10.  
  11. Remove the oil pan bolts.
  12.  
  13. With the oil pan lowered down from the block, remove the oil pump suction pipe. On 1976-77 models remove the screen. On newer models, the screen is attached to the pick-up tube.
  14.  
  15. Remove the oil pan through the front of the car. On vehicles equipped with manual transmission, lower the oil pan about 1 inch, rotate the front of the pan to the right and the rear to the left. Tilt the pan 45 degrees and remove it.
  16.  

Most 1978-88 engines have RTV sealer in between the block and the oil pan. These can be identified by a smooth sealing surface on the oil pan rather than having a raised bead. These units MUST be reassembled using RTV sealer. The use of a gasket may allow an oil leak to develop.

Conversely, if the oil pan has a raised bead, a gasket MUST be used for reinstallation. The use of RTV sealer in this case could cause an oil leak to develop.

Before installing an oil pan using RTV, it is necessary to remove all old RTV sealer which is loose or will interfere with the installation. All old RTV need not be removed. The new sealer may be placed on top of the remaining RTV.

  1. Install a new oil pump suction pipe and screen seal in the oil pump.
  2.  
  3. Lay the suction pipe and screen in the oil pan.
  4.  
  5. Clean the mating surfaces of the block and oil pan as necessary. Apply RTV or a gasket to the oil pan.
  6.  
  7. Tilt the pan and install it under the block.
  8.  
  9. Attach the oil pan bolts. Tighten to 6 Nm (55 in. lbs.). On oil pans using RTV sealer, the bolts must be attached while the sealer is still wet.
  10.  
  11. Replace the rack and pinion-to-front crossmember bolts.
  12.  
  13. Attach the exhaust pipe to the manifold.
  14.  
  15. Lower the engine on to the engine mounts and remove the lifting tool. Attach the mounting nuts and clips.
  16.  
  17. Install the heater core housing.
  18.  
  19. Connect the fuel line to the charcoal canister.
  20.  
  21. If equipped with air conditioning, install the condenser assembly and attach the radiator support.
  22.  
  23. Install the radiator and attach the hoses.
  24.  
  25. If equipped with automatic transmission, connect the cooler lines to the radiator.
  26.  
  27. Install the upper radiator support.
  28.  
  29. On air conditioning equipped models, install the upper half of the fan shroud.
  30.  
  31. Refill the cooling system.
  32.  
  33. Refill the crankcase with oil.
  34.  
  35. Start the engine and check for leaks.
  36.  

TURBO HYDRA-MATIC 200 AUTOMATIC TRANSMISSION
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the heater housing assembly from the front of the dash and rest on top of the engine.
  6.  
  7. Pull back the motor mount wire restraints and remove the motor mount pins.
  8.  
  9. Remove the radiator upper support or fan shroud, as necessary.
  10.  
  11. Raise the vehicle and drain the crankcase.
  12.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the flywheel splash shield.
  2.  
  3. Remove the rack and pinion assembly.
  4.  
  5. Loosen the converter to rear exhaust pipe clamp bolts.
  6.  
  7. Install tool J-26436 and raise the engine.
  8.  
  9. Remove the oil pan bolts and remove the oil pan.
  10.  

Most 1978 engines have RTV sealer in between the block and the oil pan. These can be identified by a smooth sealing surface on the oil pan rather than having a raised bead. These units MUST be reassembled using RTV sealer. The use of a gasket may allow an oil leak to develop.

Conversely, if the oil pan has a raised bead, a gasket MUST be used for reinstallation. The use of RTV sealer in this case could cause an oil leak to develop.

Before installing an oil pan using RTV, it is necessary to remove all old RTV sealer which is loose or will interfere with the installation. All old RTV need not be removed. The new sealer may be placed on top of the remaining RTV.

  1. Place a bead of RTV sealant on the oil pan and while still wet position up against the block. Install the attaching bolts and tighten to 6 Nm (55 in. lbs.).
  2.  
  3. Lower the engine onto the mounts and remove tool J-26436.
  4.  
  5. Tighten the converter to rear exhaust pipe clamp bolts to 23 ft. lbs.
  6.  
  7. Install the rack and pinion to the front crossmember. Tighten the bolts to 14 ft. lbs.
  8.  
  9. Install the flywheel and lower the vehicle.
  10.  
  11. Install the radiator upper support or fan shroud.
  12.  
  13. Install the engine mount nuts. Tighten the nuts to 48 ft. lbs., then position the wire restraints.
  14.  
  15. Install the heater assembly to the front of the dash.
  16.  
  17. Fill the crankcase with oil.
  18.  
  19. Install the air cleaner and the negative battery cable. Start the engine and check for leaks.
  20.  

Diesel Engine


Click image to see an enlarged view

Fig. Fig. 2View of the oil pan assembly for a diesel engine

  1. Remove the engine as detailed earlier in this section.
  2.  
  3. Support the engine on a stand.
  4.  
  5. Unscrew the nuts and bolts attaching the oil pan to the crankcase and then remove the pan.
  6.  
  7. Clean the mating surfaces of the oil pan and the block. Apply a suitable liquid gasket to the front and rear mating surfaces and then install a new gasket.
  8.  
  9. Install the oil pan retaining bolts and tighten them to 5 ft. lbs.
  10.  
  11. Reinstall the engine.
  12.  

 
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