GM Cavalier/Sunfire 1995-2000 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION



2.2L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the crankcase. Raise and support the front of the vehicle.
  4.  
  5. Unfasten the exhaust shield and disconnect the exhaust pipe at the manifold.
  6.  
  7. Remove the starter motor and position it out of the way.
  8.  
  9. Remove the flywheel cover.
  10.  
  11. On care equipped with automatic transaxle, remove the oil filter and extension.
  12.  
  13. Unfasten the oil pan bolts and remove the oil pan.
  14.  



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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 hae 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. Tighten the oil pan retaining bolts to 89 inch lbs. (10 Nm).
  6.  
  7. On care 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.  

2.3L and 2.4L Engines

See Figures 2 and 3

  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Properly drain the engine oil and the cooling system into suitable containers.
  4.  
  5. Remove the flywheel housing or transaxle converter cover, as applicable.
  6.  
  7. Remove the right front wheel and tire assembly, then remove the right splash shield.
  8.  
  9. Remove the serpentine drive belt.
  10.  
  11. Unfasten the A/C compressor lower retaining bolts.
  12.  
  13. Remove the transaxle-to-engine brace.
  14.  
  15. Disconnect the engine mount strut bracket.
  16.  
  17. Unfasten the radiator outlet pipe bolts, then remove the pipes from the oil pan.
  18.  
  19. Remove the exhaust manifold brace.
  20.  
  21. Unfasten the oil pan-to-flywheel cover bolt and nut.
  22.  
  23. Remove the flywheel cover stud for clearance.
  24.  
  25. Disconnect the radiator outlet pipe from the lower radiator hose and oil pan.
  26.  
  27. Detach the oil level sensor connector.
  28.  
  29. Unfasten the oil pan retaining bolts, then remove the pan and gasket. Inspect the gasket for damage. If it'e O.K. you can reuse it. No sealer is necessary.
  30.  



Click image to see an enlarged view

Fig. Fig. 2: After removing the oil pan, inspect the gasket. If it's not damaged you can reuse it

To install:
  1. Position the gasket, then install the oil pan. Loosely install the retaining bolts.
  2.  
  3. Place the spacer in its approximate installed location by allow clearance to tighten the pan bolt directly above the spacer. Tighten the oil pan bolts to the specifications given in the accompanying figure.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Oil pan tightening specifications-2.3L and 2.4L engines

  1. Position the spacer into its proper position, then install the stud.
  2.  
  3. Fasten the oil pan-to-transaxle nut.
  4.  
  5. Attach the oil level sensor connector.
  6.  
  7. Connect the radiator outlet pipe to the oil pan and fasten with the retaining bolts.
  8.  
  9. Install the engine mount strut bracket.
  10.  
  11. Fasten the transaxle-to-engine brace.
  12.  
  13. Secure the A/C compressor bolts.
  14.  
  15. Install the serpentine drive belt.
  16.  
  17. Fasten the right splash shield, then install the wheel and tire assembly.
  18.  
  19. Install the flywheel housing or transaxle converter cover.
  20.  
  21. Fill the cooling system and engine crankcase with the correct type of fluids.
  22.  
  23. Connect the negative battery cable.
  24.  

 
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