GM Corsica/Beretta 1988-1996 Repair Guide

Oil Pan

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REMOVAL & INSTALLATION




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.

2.0L and 2.2L Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. For6994-96 vehicles, remove the right front tire and wheel assembly, then remove the right engine splash shield.
  6.  
  7. Position a suitable drain pan under the oil pan, then drain the engine oil. Don&rsquot forget to install the drain plug, after the oil is fully drained.
  8.  
  9. If equipped, remove the A/C brace.
  10.  
  11. For6988-93 vehicles, remove the exhaust heat shield, then disconnect the exhaust pipe from the manifold.
  12.  
  13. Remove the starter bracket from the block, then remove the starter motor and position it out of the way.
  14.  
  15. Remove the transaxle converter cover or flywheel housing cover.
  16.  
  17. For6988-90 vehicles, remove the four right support bolts. Lower the support slightly to gain clearance for oil pan removal.
  18.  
  19. For6988-90 vehicles if equipped with automatic transaxle, remove the oil filter and extension.
  20.  
  21. For6994-96 vehicles, remove the engine mount strut bracket. Remove the oil level sensor.
  22.  
  23. Remove the oil pan nuts and bolts, then lower the oil pan and remove it from the vehicle.
  24.  

Before installing the oil pan, make sure 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.

To install:
  1. Apply a 1 / 10 in. (2mm) wide bead of RTV sealant to the oil pan sealing surface, except for at the rear seal mounting surface. Apply a thin coat of RTV sealer on a new oil pan rear seal, on the ends down to the ears, then install the pan against the case and install bolts. Tighten the bolts to 71-89 inch lbs. (8-10 Nm).
  2.  
  3. For6994-96 vehicles, install the oil level sensor and the engine mount strut bracket.
  4.  
  5. For6988-90 cars equipped with automatic transmission, install the oil filter adapter seal and oil filter adapter.
  6.  
  7. If removed, raise the right support into position, then secure using the four retaining bolts.
  8.  
  9. Install the starter motor and bracket.
  10.  
  11. Install the transaxle converter cover or flywheel housing cover.
  12.  
  13. For6988-93 vehicles, attach the exhaust pipe to the manifold, then install the heat shield.
  14.  
  15. If equipped, remove the A/C brace.
  16.  
  17. If removed, install the right front engine shield, and the right front wheel and tire assembly.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Fill the crankcase with the proper type and amount of engine oil.
  22.  
  23. Connect the negative battery cable, then start the engine and check for leaks. Recheck the oil level and add if necessary.
  24.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the oil pan and seal mounting - 2.0L and 2.2L engines

2.3L Engine

See Figures 2, 3 and 4

1990-91 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the flywheel inspection cover.
  6.  
  7. Remove the splash shield-to-suspension support bolt.
  8.  
  9. Remove the exhaust manifold brace.
  10.  
  11. Remove the radiator outlet pipe-to-oil pan bolt.
  12.  
  13. Remove the transaxle-to-oil pan nut and stud using a 7mm socket.
  14.  
  15. Gently pry the spacer out from between oil pan and transaxle.
  16.  
  17. Unfasten the oil pan bolts, then remove the oil pan from the engine.
  18.  

To install:
  1. Position the oil pan to the engine and secure with the retaining bolts. Tighten the chain housing and carrier seal bolts to606 inch lbs. (12 Nm). Tighten the oil pan-to-block bolts to67 ft. lbs. (23 Nm).
  2.  
  3. Install the spacer and install the stud.
  4.  
  5. Install the oil pan-to-transaxle nut and bolt.
  6.  
  7. Install the splash shield-to-suspension support bolt.
  8.  
  9. Install the radiator outlet pipe-to-oil pan bolt.
  10.  
  11. Install the exhaust manifold brace.
  12.  
  13. Install the flywheel inspection cover.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Fill the crankcase with the proper type and amount of engine oil.
  18.  
  19. Connect the negative battery cable. Start the engine and check for leaks.
  20.  
  21. Turn the engine off and allow to stand. Check the oil level and add as necessary to obtain the proper level.
  22.  



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Fig. Fig. 2: Oil pan fastener location and tightening specifications - 2.3L engines



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Fig. Fig. 3: Engine-to-transaxle attachment, as shown from the rear side -6990-92 2.3L engines



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Fig. Fig. 4: Exploded view of the engine-to-transaxle attachment -6993-94 2.3L engine

1992-94 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Position a suitable drain pan under the oil pan, then drain the oil pan.
  6.  
  7. Place another drain pan under the radiator, then drain the cooling system.
  8.  
  9. Remove the flywheel cover.
  10.  
  11. Remove the right front wheel and tire assembly and the right side splash shield.
  12.  
  13. Relieve the serpentine drive belt tension, then remove the belt.
  14.  
  15. Disconnect the engine mount strut from the engine mount strut bracket.
  16.  
  17. If equipped, remove the A/C compressor from the bracket and suitably support out of the way. Do NOT disconnect the refrigerant lines.
  18.  
  19. Remove the engine mount strut bracket bolts and move the bracket aside.
  20.  
  21. Remove the radiator outlet pipe bolts.
  22.  
  23. Disconnect the air conditioner and radiator outlet pipes from the suspension supports.
  24.  
  25. Remove the exhaust manifold brace.
  26.  
  27. Remove the oil pan-to-flywheel cover bolt and nut.
  28.  
  29. Remove the flywheel cover stud for clearance.
  30.  
  31. Disconnect the radiator outlet pipe from the lower hose and oil pan.
  32.  
  33. Disconnect the oil level sensor wire.
  34.  
  35. Unfasten the oil pan bolts and remove the oil pan. Thoroughly clean the pan mating surfaces, discard the oil pan gasket.
  36.  

To install:
  1. Position a new gasket in the groove of the oil pan, then install the pan and new gasket (no sealer is needed). Loosely install the pan bolts.
  2.  
  3. Place the spacer in its approximate installed location but allow clearance to tighten the pan bolt directly above the spacer.
  4.  
  5. Tighten the chain housing and carrier seal bolts to606 inch lbs. (12 Nm). Tighten the oil pan-to-block bolts to67 ft. lbs. (23 Nm).
  6.  
  7. Place the spacer into its proper location and install the stud.
  8.  
  9. Install the oil pan-to-transaxle nut and tighten to 41 ft. lbs. (56 Nm).
  10.  
  11. Attach the oil level sensor wire.
  12.  
  13. Connect the radiator outlet pipe to the lower hose and oil pan.
  14.  
  15. Install the exhaust manifold brace.
  16.  
  17. Connect the air conditioner and radiator outlet pipes to the suspension supports.
  18.  
  19. Install the radiator outlet pipe bolts.
  20.  
  21. Install the engine mount strut bracket bolts.
  22.  
  23. If equipped, install the air conditioner compressor.
  24.  
  25. Connect the engine mount strut to the engine mount strut bracket.
  26.  
  27. Install the serpentine drive belt.
  28.  
  29. Install the right splash shield, then install the right front wheel and tire assembly.
  30.  
  31. Install the flywheel cover.
  32.  
  33. Carefully lower the vehicle.
  34.  
  35. Fill the cooling system and the crankcase with the proper type and amount of fluids.
  36.  
  37. Connect the negative battery cable. Start the engine and check for leaks.
  38.  
  39. Turn the engine off and allow to stand. Check the fluid levels and add as necessary to obtain the proper levels.
  40.  

2.8L and 3.1L Engines
1988-93 VEHICLES

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle with jackstands.
  4.  
  5. Position a suitable container under the oil pan, then drain the engine oil. Don&rsquot forget to install the drain plug, after the oil has completely drained.
  6.  
  7. Remove the starter.
  8.  
  9. Remove the bellhousing/flywheel inspection cover.
  10.  
  11. Unfasten the oil pan retaining bolts, then lower and remove the oil pan from the vehicle.
  12.  
  13. Remove and discard the oil pan gasket. Thoroughly clean the oil pan flanges, rail, front cover, rear main bearing cap and the threaded bolt holes.
  14.  

To install:
  1. Position a new gasket in the groove on the oil pan. If the rear main bearing cap is being installed, then GM sealant605080 or equivalent, must be placed on the oil pan gasket tabs that insert into the gasket groove of the outer surface on the rear main bearing cap.
  2.  
  3. Position the oil pan and secure with the retaining bolts. Tighten the 2 rear oil pan bolts to68 ft. lbs. (25 Nm), and the remaining oil pan bolts and nuts to 71-89 inch lbs. (8-10 Nm).
  4.  
  5. Install the flywheel inspection/bellhousing.
  6.  
  7. Install the starter motor.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Fill the crankcase with the proper type and amount of engine oil. Connect the negative battery cable, then start the engine and check for leaks.
  12.  
  13. Turn the engine off and allow to stand. Check the fluid levels and add as necessary to obtain the proper levels.
  14.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the oil pan and bolt tightening specifications -1988-93 2.8L and 3.1L engines

1994-96 VEHICLES

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. If equipped, loosen but do not remove the upper A/C compressor.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Position a suitable container under the oil pan, then drain the engine oil. Don&rsquot forget to install the drain plug, after the oil has completely drained.
  10.  
  11. Remove the right front wheel and tire assembly, then remove the splash shield.
  12.  
  13. Remove the engine mount strut from the suspension support.
  14.  
  15. Detach the right front ABS wheel speed sensor harness from the right suspension support.
  16.  
  17. Remove the right front ball joint.
  18.  
  19. Remove the right side stabilizer link. Remove the right side suspension support.
  20.  
  21. If equipped, remove the lower A/C compressor bolts, then position the compressor aside and support. Do NOT disconnect the refrigerant lines.
  22.  
  23. Remove the engine mount strut bracket.
  24.  
  25. Remove the engine-to-transaxle brace.
  26.  
  27. Remove the oil filter and the oil filter adapter, if equipped.
  28.  
  29. Remove the starter motor from the vehicle.
  30.  
  31. Remove the flywheel inspection cover.
  32.  
  33. Detach the oil level sensor electrical connector.
  34.  
  35. Unfasten the oil pan retaining bolts, then lower and remove the oil pan from the vehicle.
  36.  
  37. Remove and discard the oil pan gasket. Thoroughly clean the oil pan flanges, rail, front cover, rear main bearing cap and the threaded bolt holes.
  38.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the oil pan mounting -1994-96 3.1L engines

To install:
  1. Position a new gasket in the groove on the oil pan. If the rear main bearing cap is being installed, then GM sealant605080 or equivalent, must be placed on the oil pan gasket tabs that insert into the gasket groove of the outer surface on the rear main bearing cap.
  2.  
  3. Position the oil pan and secure with the retaining bolts. Tighten the retaining bolts to68 ft. lbs. (25 Nm).
  4.  
  5. Install the oil pan side bolts, then tighten to 37 ft. lbs. (3 Nm).
  6.  
  7. Attach the oil level sensor electrical connector.
  8.  
  9. Install the transaxle converter cover.
  10.  
  11. Install the starter motor.
  12.  
  13. Install the oil filter.
  14.  
  15. Install the engine-to-transaxle brace.
  16.  
  17. Install the engine mount strut bracket.
  18.  
  19. Loosely assembly the A/C compressor spacer and upper bolts, then secure in place.
  20.  
  21. Install the A/C compressor to the engine.
  22.  
  23. Install the right side suspension support. Install the right side stabilizer bar.
  24.  
  25. Install the right side ball joint.
  26.  
  27. Attach the right front ABS wheel speed sensor wiring harness.
  28.  
  29. Install the engine mount strut to the suspension support.
  30.  
  31. Install the right splash shield, then install the wheel and tire assembly.
  32.  
  33. Carefully lower the vehicle.
  34.  
  35. Install the serpentine drive belt.
  36.  
  37. Fill the crankcase with the proper type and amount of engine oil. Connect the negative battery cable, then start the engine and check for leaks.
  38.  
  39. Turn the engine off and allow to stand. Check the fluid levels and add as necessary to obtain the proper levels.
  40.  

See Figures 7 through 25



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Fig. Fig. 7: Loosen the engine mount strut bracket side retaining bolt ...



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Fig. Fig. 8: ... then remove the bolt from the bracket



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Fig. Fig. 9: Make sure to remove all the bolts from the engine mount strut bracket



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Fig. Fig. 10: Remove the engine mount strut retaining bolt(s) ...



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Fig. Fig. 11: ... then remove the engine mount strut from the vehicle



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Fig. Fig. 12: Unfasten the right side suspension support retaining bolts ...



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Fig. Fig. 13: ... then remove the right side suspension support from the vehicle



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Fig. Fig. 14: Unfasten the lower A/C compressor mounting bolts ...



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Fig. Fig. 15: ... then remove the bolts and reposition the compressor, but DO NOT disconnect the lines



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Fig. Fig. 16: Place a drain pan under the oil filter when removing it, because it can get messy



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Fig. Fig. 17: If necessary, remove the oil filter adapter retaining bolts ...



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Fig. Fig. 18: ... then remove the oil filter adapter from the vehicle



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Fig. Fig. 19: Remove the flywheel inspection cover bolts ...



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Fig. Fig. 20: ... then remove the inspection cover from the vehicle.



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Fig. Fig. 21: Unplug the oil level sensor electrical connector



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Fig. Fig. 22: Remove the oil pan side retaining bolts



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Fig. Fig. 23: Unfasten the front oil pan mounting bolts ...



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Fig. Fig. 24: ... then carefully lower the oil pan and remove it from the vehicle



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Fig. Fig. 25: Remove the oil pan gasket and replace it with a new one during installation

 
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