Corvette 1997-2005

Oil Pan

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Front crossmember
     
    Oil filter
     
    Automatic transmission cooler line front and rear retaining clamp bolts
     
    Engine flywheel to oil pan bolts
     
    Engine flywheel close out bolts
     
    Engine oil level sensor
     
    Engine oil temperature sensor electrical connector
     
    Oil pan
     
    Oil pan gasket and discard it. Drill out the oil pan retaining rivets

    Click image to see an enlarged view

    Fig. Apply sealant to the areas where the front and rear covers attach to the engine block-5.7L engine



    Click image to see an enlarged view

    Fig. Exploded view of the oil pan mounting-5.7L engine

     

  6.  

To install:

  1. Apply a 0.20 in. (5mm) bead of RTV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface.
  2.  
  3. Install or connect the following:

    New gasket on the oil pan. It is not necessary to rivet the new gasket on the oil pan.
     
    Oil pan and hand tighten the bolts
     
    Two lower flywheel housing bolts and hand tighten them
     
    Oil pan to engine bolts. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Oil pan front cover bolts. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Oil pan rear cover bolts. Torque the bolts to 106 inch lbs. (12 Nm).
     
    Flywheel housing bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Left and right close out and bolts. Torque the bolts to 106 inch lbs. (12 Nm).
     
    Engine oil temperature sensor electrical connector
     
    Engine oil level sensor. Torque the sensor to 115 inch lbs. (13 Nm).
     
    Automatic transmission cooler pipe front retaining clamp bolt. Torque the bolt to 106 inch lbs. (12 Nm).
     
    Automatic transmission cooler pipe rear retaining clamp bolt. Torque the bolt to 22 inch lbs. (3 Nm).
     
    Oil filter. Torque the filter to 22 ft. lbs. (30 Nm).
     
    Oil drain plug. Torque the plug to 18 ft. lbs. (25 Nm).
     
    Front crossmember
     
    Negative battery cable
     

  4.  
  5. Fill the engine with new oil.
  6.  
  7. Check and top off all fluids.
  8.  
  9. Start the vehicle and check for leaks, repair if necessary.
  10.  
  11. Check and adjust the front end alignment.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Support the engine with a suitable engine support fixture.
  6.  
  7. Remove front suspension crossmember:

    Negative battery cable
     
    Alternator
     
    Washer pump/reservoir
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Headlamp electrical connector
     
    Tie rods from the steering linkage
     
    Real Time Damping (RTD) sensor links, if equipped
     
    Stabilizer shaft
     
    Intermediate shaft from the steering gear
     
    Electronic Brake Control Module/Brake Pressure Modulator Valve (EBCM/BPMV) bracket and reposition
     
    Power steering fluid cooler from the crossmember
     
    Power steering gear off the crossmember and support aside
     
    Lower shock absorber mounting bolts
     
    Transverse leaf spring using a suitable compressor
     
    Lower control arm bolts from the suspension crossmember
     
    Engine mount lower nuts
     
    Wheel Speed Sensor (WSS) wiring harness from the crossmember
     
    Brake line from the crossmember
     
    Remove the crossmember mounting nuts and lower the crossmember out of the vehicle.
     

  8.  
  9. Remove or disconnect the following:
    NOTE
    It may be necessary to rotate the oil pan when removing to clear the oil pump pick up tube.



    Oil filter
     
    Left rear transmission cover
     
    Starter motor
     
    Right transmission cover
     
    Engine oil level sensor electrical connector
     
    Transmission lines from the rear of the oil pan, where applicable
     
    Transmission lines from the front of the oil pan, where applicable
     
    Oil cooler bolts
     
    Rear oil pan bolts
     
    Clutch housing-to-oil pan bolts, where applicable
     
    Remaining oil pan bolts
     
    Oil pan and gasket
     

  10.  

To install:


NOTE
The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission housing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan are flush, or even. The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing plane.


NOTE
Do not reuse the oil pan gasket again. It is not necessary to rivet the new gasket to the oil pan.

  1. Apply a 5mm (0.20 inch) bead of RTV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface.

    Click image to see an enlarged view

    Fig. Apply a 5mm (0.20 inch) bead of sealant 20 mm (0.8 inch) long to the engine block (front)



    Click image to see an enlarged view

    Fig. Apply a 5mm (0.20 inch) bead of sealant 20 mm (0.8 inch) long to the engine block (rear)

  2.  
  3. Pre-assemble the oil pan gasket to the pan.

    Install the gasket onto the oil pan
     
    Install the oil pan bolts to the pan and through the gasket
     

  4.  
  5. Install the oil pan, gasket and bolts to the engine block.
  6.  
  7. Tighten bolts finger tight. Do not overtighten.
  8.  
  9. Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces.
  10.  
  11. Align the oil pan until the rear of engine block and rear of oil pan are flush or even.
  12.  
  13. Tighten the oil pan-to-block and oil pan-to-front cover bolts, M8 bolts, to 18 ft. lbs. (25 Nm).
  14.  
  15. Tighten the oil pan-to-rear cover bolts,M6 bolts, to 106 inch lbs. (12 Nm).
  16.  
  17. Measure the oil pan-to-engine block alignment(a).

    Click image to see an enlarged view

    Fig. Measure the oil pan-to-engine block alignment at points shown

  18.  
  19. Place a straight edge across the rear of the engine block and rear of oil pan at the transmission housing mounting surfaces.
    NOTE
    The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing mounting surfaces.

  20.  
  21. Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface, and inspect to ensure there is no greater than a 0.1 mm (0.004 in) gap (a) between the pan and straight edge.
  22.  
  23. If the oil pan alignment is not within specifications, remove the oil pan and repeat the above procedure.
  24.  
  25. Install or connect the following:

    Clutch housing-to-oil pan bolts, where applicable
     
    Rear oil pan bolts
     
    Oil cooler bolts
     
    Transmission lines from the front of the oil pan, where applicable
     
    Transmission lines from the rear of the oil pan, where applicable
     
    Engine oil level sensor electrical connector
     
    Right transmission cover, tighten bolt to 106 inch lbs. (12 Nm)
     
    Starter motor
     
    Left rear transmission cover, tighten bolt to 106 inch lbs. (12 Nm)
     
    Oil filter
     
    Reinstall the front crossmember and tighten to 81 ft. lbs. (110 Nm)
     
    Brake line to the crossmember
     
    Wheel Speed Sensor (WSS) wiring harness to the crossmember
     
    Engine mount lower nuts. Tighten to 48 ft. lbs. (65 Nm)
     
    Lower control arm bolts from the suspension crossmember
     
    Transverse leaf spring using a suitable compressor
     
    Lower control arm to the crossmember, Do not tighten the bolts until the front end alignment is correct
     
    Lower shock absorber mounting bolts and torque them to 21 ft. lbs. (28 Nm)
     
    Power steering gear and torque the bolts to 74 ft. lbs. (100 Nm)
     
    EBCM/BPMV bracket and torque the bolts to 20 ft. lbs. (27 Nm)
     
    Intermediate shaft and torque the pinch bolt to 25 ft. lbs. (35 Nm)
     
    Outer tie rods and torque the nuts to 18 ft. lbs. (25 Nm) plus an additional 180 degree turn
     
    RTD sensor electrical connector, if equipped
     
    Stabilizer shaft and torque the link nuts to 53 ft. lbs. (72 Nm) and the clamp bolts to 43 ft. lbs. (58 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Washer reservoir and torque the nuts to 66 inch lbs. (7.5 Nm)
     
    ECT sensor electrical connector
     
    Front headlamp electrical connector
     
    Reconnect the negative battery cable
     

  26.  
  27. Fill the engine with oil to the correct level.
  28.  
  29. Start the vehicle and check for leaks.
  30.  
  31. Check and adjust the front end alignment. Tighten the lower control arm bolts to 125 ft. lbs. (170 Nm).
  32.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Alternator
     
    Washer reservoir
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Headlamp electrical connector
     
    Tie rods from the steering linkage
     
    Real Time Damping (RTD) sensor links, if equipped
     
    Stabilizer shaft
     
    Intermediate shaft from the steering gear
     
    Electronic Brake Control Module/Brake Pressure Modulator Valve (EBCM/BPMV) bracket and reposition
     
    Power steering gear
     
    Lower shock absorber mounting bolts
     
    Transverse leaf spring using a suitable compressor
     
    Lower control arm bolts from the suspension crossmember
     
    Engine mount lower nuts
     
    Wheel Speed Sensor (WSS) wiring harness from the crossmember
     
    Brake line from the crossmember
     

  6.  
  7. Support the suspension crossmember.
    NOTE
    To remove the oil pan gasket it is necessary to drill out 3 rivets securing it to the pan.



    Crossmember mounting nuts
     
    Front crossmember
     
    Oil filter
     
    Automatic transmission cooler line front and rear retaining clamp bolts (if equipped)
     
    Engine flywheel housing-to-oil pan bolts
     
    Engine flywheel close out bolts
     
    Engine oil level sensor
     
    Engine oil temperature sensor electrical connector
     
    Oil pan assembly
     
    Lower oil pan bolts and separate the pans (if necessary)
     



    Click image to see an enlarged view

    Fig. Separate the upper (1) and lower (3) oil pans



    Click image to see an enlarged view

    Fig. Apply sealant to the areas where the front and rear covers attach to the engine block



    Click image to see an enlarged view

    Fig. Exploded view of the oil pan mounting

  8.  

To install:

  1. If separated, connect the upper and lower oil pans with a new gasket and torque the bolts to 106 inch lbs. (12 Nm).
  2.  
  3. Apply a 0.20 in. (5mm) bead of RTV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface.
  4.  
  5. Install or connect the following:

    New gasket on the oil pan. It is not necessary to rivet the new gasket on the oil pan.
     
    Oil pan and hand-tighten the bolts
     
    Oil pan-to-engine bolts and torque them to 18 ft. lbs. (25 Nm)
     
    Oil pan-to-front cover bolts and torque them to 18 ft. lbs. (25 Nm)
     
    Oil pan-to-rear cover bolts and torque them to 106 inch lbs. (12 Nm)
     
    Flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Left and right close outs and bolts and torque the bolts to 106 inch lbs. (12 Nm)
     
    Engine oil temperature sensor electrical connector
     
    Engine oil level sensor and torque it to 26 ft. lbs. (35 Nm)
     
    Automatic transmission cooler pipe front retaining clamp bolt and torque it to 106 inch lbs. (12 Nm)
     
    Automatic transmission cooler pipe rear retaining clamp bolt and torque it to 22 inch lbs. (3 Nm)
     
    Oil filter and torque it to 22 ft. lbs. (30 Nm)
     
    Oil drain plug and torque it to 18 ft. lbs. (25 Nm)
     

  6.  
  7. Raise the suspension crossmember into position.

    Crossmember mounting nuts and torque them to 81 ft. lbs. (110 Nm)
     
    Engine mount lower nuts and torque them to 48 ft. lbs. (65 Nm)
     
    WSS wiring harness to the crossmember
     
    Brake line to the crossmember
     
    Transverse leaf spring
     
    Lower control arm to the crossmember, DO NOT torque the bolts at this time
     
    Lower shock absorber mounting bolts and torque them to 21 ft. lbs. (28 Nm)
     
    Power steering gear and torque the bolts to 74 ft. lbs. (100 Nm)
     
    EBCM/BPMV bracket and torque the bolts to 20 ft. lbs. (27 Nm)
     
    Intermediate shaft and torque the pinch bolt to 25 ft. lbs. (35 Nm)
     
    Outer tie rods and torque the nuts to 18 ft. lbs. (25 Nm) plus an additional 180 degree turn
     
    RTD sensor electrical connector, if equipped
     
    Stabilizer shaft and torque the link nuts to 53 ft. lbs. (72 Nm) and the clamp bolts to 43 ft. lbs. (58 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Washer reservoir and torque the nuts to 66 inch lbs. (7.5 Nm)
     
    ECT sensor electrical connector
     
    Front headlamp electrical connector
     
    Negative battery cable
     

  8.  
  9. Fill the engine with new oil.
  10.  
  11. Start the vehicle and check for leaks, repair if necessary.
  12.  
  13. Check and adjust the front end alignment.
  14.  
  15. Torque the lower control arm bolts to 125 ft. lbs. (170 Nm).
  16.  

6.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Support the engine with a suitable engine support fixture.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Alternator
     
    Washer pump/reservoir
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Headlamp electrical connector
     
    Tie rods from the steering linkage
     
    Real Time Damping (RTD) sensor links, if equipped
     
    Stabilizer shaft
     
    Intermediate shaft from the steering gear
     
    Electronic Brake Control Module/Brake Pressure Modulator Valve (EBCM/BPMV) bracket and reposition
     
    Power steering fluid cooler from the crossmember
     
    Power steering gear off the crossmember and support aside
     
    Lower shock absorber mounting bolts
     
    Transverse leaf spring using a suitable compressor
     
    Lower control arm bolts from the suspension crossmember
     
    Engine mount lower nuts
     
    Wheel Speed Sensor (WSS) wiring harness from the crossmember
     
    Brake line from the crossmember
     

  8.  
  9. Remove the crossmember mounting nuts and lower the crossmember out of the vehicle.
  10.  
  11. Remove or disconnect the following:
    NOTE
    It may be necessary to rotate the oil pan when removing to clear the oil pump pick up tube.



    Oil filter
     
    Left rear transmission cover
     
    Starter motor
     
    Right transmission cover
     
    Engine oil level sensor electrical connector
     
    Transmission lines from the rear of the oil pan
     
    Transmission lines from the front of the oil pan
     
    Rear oil pan bolts
     
    Clutch housing-to-oil pan bolts
     
    Remaining oil pan bolts
     
    Oil pan and gasket
     

  12.  

To install:


NOTE
Do not reuse the oil pan gasket again. It is not necessary to rivet the new gasket to the oil pan.

  1. Apply a 0.20 in. (5mm) bead of RTV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface.
  2.  
  3. Install the oil pan and hand tighten 2 bolts to hold it in place.
  4.  
  5. Tighten the oil pan mounting bolts as follows:
    1. M6 bolts to 106 inch lbs. (12 Nm)
    2.  
    3. M8 bolts to 18 ft. lbs. (25 Nm)
    4.  

  6.  
  7. Install or connect the following:

    Oil level sensor
     
    Right transmission cover. Tighten bolt to 106 inch lbs. (12 Nm).
     
    Front and rear transmission cooler lines. Tighten the retainers to 106 inch lbs. (12 Nm).
     
    Starter motor
     
    Left rear transmission cover. Tighten bolt to 106 inch lbs. (12 Nm).
     
    Oil filter
     

  8.  
  9. Raise the suspension crossmember into position.
  10.  
  11. Install or connect the following:

    Crossmember mounting nuts. Tighten to 81 ft. lbs. (110 Nm).
     
    Engine mount lower nuts. Tighten to 48 ft. lbs. (65 Nm).
     
    WSS wiring harness to the crossmember
     
    Brake line to the crossmember
     
    Transverse leaf spring
     
    Lower control arm to the crossmember, Do not tighten the bolts until the front end alignment is correct.
     
    Lower shock absorber mounting bolts and torque them to 21 ft. lbs. (28 Nm)
     
    Power steering gear and torque the bolts to 74 ft. lbs. (100 Nm)
     
    EBCM/BPMV bracket and torque the bolts to 20 ft. lbs. (27 Nm)
     
    Intermediate shaft and torque the pinch bolt to 25 ft. lbs. (35 Nm)
     
    Outer tie rods and torque the nuts to 18 ft. lbs. (25 Nm) plus an additional 180 degree turn
     
    RTD sensor electrical connector, if equipped
     
    Stabilizer shaft and torque the link nuts to 53 ft. lbs. (72 Nm) and the clamp bolts to 43 ft. lbs. (58 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Washer reservoir and torque the nuts to 66 inch lbs. (7.5 Nm)
     
    ECT sensor electrical connector
     
    Front headlamp electrical connector
     
    Negative battery cable
     

  12.  
  13. Fill the engine with oil to the correct level.
  14.  
  15. Start the vehicle and check for leaks.
  16.  
  17. Check and adjust the front end alignment. Tighten the lower control arm bolts to 125 ft. lbs. (170 Nm).
  18.