GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Oil Pan

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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.

REMOVAL & INSTALLATION



1.8L, 2.0L and 2.2L OHV Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the crankcase. Raise and support the front of the vehicle.
  4.  
  5. On 1982-86 models, remove the air conditioning brace at the starter and air conditioning bracket.
  6.  
  7. Unfasten the exhaust shield and disconnect the exhaust pipe at the manifold.
  8.  
  9. Remove the starter motor and position it out of the way.
  10.  
  11. Remove the flywheel cover.
  12.  
  13. On 1982-90 models, remove the 4 right support bolts. Lower the support slightly to gain clearance for oil pan removal.
  14.  
  15. On cars equipped with automatic transmission, remove the oil filter and extension.
  16.  
  17. Unfasten the oil pan bolts and remove the oil pan.
  18.  



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Fig. Fig. 1: Oil pan installation - 1995 2.2L OHV engine shown

To install:
  1. Prior to oil pan installation, check that the sealing surfaces on the pan, cylinder block and front cover are clean and free of oil. If installing the old pan, be sure that all old RTV has been removed.
  2.  
  3. Apply a 1 / 8 in. (3mm) bead of RTV sealant to the oil pan sealing surface. Use a new oil pan rear seal and apply a thin coat of RTV sealant to the ends of the gasket down to the ears and install the pan in place.
  4.  
  5. On 1982-86 models, tighten the front bolts to 7-13 ft. lbs., the rear bolts to 11-18 ft. lbs., the stud to 5-7 ft. lbs., and all others to 4-9 ft. lbs. (5-12 Nm). On 1987-92 models tighten the bolts to 77 inch lbs. (8.6 Nm). On 1993-96 vehicles, tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. On cars equipped with an automatic transaxle, replace the oil filter adapter seal and replace the oil filter adapter.
  8.  
  9. Install the remaining components in the reverse order of removal.
  10.  

1.8L and 2.0L OHC Engines

See Figures 2, 3, 4, 5, 6, 7, 8 and 9

  1. Raise and support the car safely.
  2.  
  3. Remove right front wheel and tire assembly.
  4.  
  5. Remove right hand splash shield.
  6.  
  7. Position jackstands at jacking points.
  8.  
  9. Drain engine oil.
  10.  
  11. If necessary on some models, remove lower air conditioning bracket strut rod attachment bolt and swing aside.
  12.  
  13. Remove exhaust pipe-to-manifold attachment bolts. On turbo models, disconnect the exhaust pipe at the wastegate. Position the pipe out of the way.
  14.  



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Fig. Fig. 2: Unfasten the exhaust pipe-to-manifold retaining bolts, then ...



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Fig. Fig. 3: Detach the exhaust pipe and position it out of the way

  1. Remove the flywheel dust cover by unfastening the four retaining bolts.
  2.  



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Fig. Fig. 4: Unfasten the flywheel dust cover retaining bolts, then ...



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Fig. Fig. 5: ... remove the flywheel dust cover

  1. Unfasten the oil pan bolts, then remove the pan and scraper.
  2.  



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Fig. Fig. 6: Unfasten the oil pan retaining bolts



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Fig. Fig. 7: Carefully lower the oil pan



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Fig. Fig. 8: Remove the oil pan assembly

To install:
  1. Clean the sealing surfaces, install the oil pan with a new gasket and apply RTV as shown in the illustration. Install the bolts to the oil pan with Loctite® on the threads. Tighten the pan bolts to 4 ft. lbs. (5 Nm).
  2.  



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Fig. Fig. 9: Clean the oil pan gasket mating surfaces

  1. Installation of the remaining components is the reverse of the removal procedure.
  2.  

2.8L and 3.1L Engines
1985-88 VEHICLES

See Figure 10

  1. Disconnect the battery ground.
  2.  
  3. Raise and support the car on jackstands.
  4.  
  5. Drain the oil.
  6.  


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 bellhousing cover.
  2.  
  3. Remove the starter.
  4.  
  5. Remove the oil pan bolts and remove the oil pan.
  6.  

To install:


Click image to see an enlarged view

Fig. Fig. 10: Installing the oil pan - 1988 2.8L engine shown

  1. Installation is the reverse of removal. On 1985-86 models, the pan is installed using RTV gasket material in place of a gasket. Make sure that the sealing surfaces are free of old RTV material. Use a 1 / 8 in. (3mm) bead of RTV material on the pan sealing flange. On 1987-88 models the pan is installed using a gasket. Torque the M8 x 1.25 x 14.0 pan bolts to 15-30 ft. lbs. (20-41 Nm) and the M6 x 1 x 16.0 pan bolts to 6-15 ft. lbs. (8-20 Nm).
  2.  

1989-94 VEHICLES

See Figure 11

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt and the tensioner.
  4.  
  5. Support the engine with tool J-28467 or equivalent.
  6.  
  7. Raise and safely support the vehicle. Drain the engine oil.
  8.  
  9. Remove the starter shield and the flywheel cover. Remove the starter.
  10.  
  11. Remove the engine to frame mount retaining nuts.
  12.  
  13. Lower the vehicle.
  14.  
  15. Support the engine using tool J-28467-A or equivalent, then raise and support the vehicle safely.
  16.  
  17. Remove the right tire and wheel assembly. Remove the right inner fender splash shield.
  18.  
  19. Unfasten the oil pan retaining bolts and nuts and remove the oil pan.
  20.  



Click image to see an enlarged view

Fig. Fig. 11: Installing the oil pan - 1994 3.1L engines

To install:
  1. Clean the gasket mating surfaces.
  2.  
  3. Install a new gasket on the oil pan. Apply silicon sealer to the portion of the pan that contacts the rear of the block.
  4.  
  5. Install the oil pan retaining nuts. Tighten the nuts to 71-89 inch lbs. (8-10 Nm).
  6.  
  7. Install the oil pan retaining bolts. Tighten the rear bolts to 18 ft. lbs. (25 Nm) and the remaining bolts to 71-89 inch lbs. (8-10 Nm).
  8.  
  9. Install the right inner fender splash shield.
  10.  
  11. Lower the vehicle and remove the engine support tool.
  12.  
  13. Raise and support the vehicle safely.
  14.  
  15. Install the engine to frame mounting nuts.
  16.  
  17. Install the starter and splash shield. Install the flywheel shield.
  18.  
  19. Lower the vehicle and fill the crankcase with oil, install the belt tensioner and belt and connect the negative battery cable. Run the engine to normal operating temperature and check for leaks.
  20.  

 
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