Removal and installation the oil pan (Opel Astra G)

Engines 1.4, 1.6 and 1.8 l

Cm. Removal and installation the oil pan - models with a cast tray.

Please note that on 1.4 and 1.6 l models the sump is installed via a gasket, which must be replaced during assembly.

When installing on 1.4 and 1.6 L models, the sealant is applied to the mating surface of the cylinder block in the areas where the oil pump housing and rear main bearing cover are joined.



On 1.8 L models, a sealant cushion of approximately 2.5 mm thickness should be applied to the entire mating surface of the mating flange; at the point where the fifth main bearing cap is mated, the thickness of the cushion should be increased to 3.5 mm.

2.0L Engines

Removal

1. Perform the procedures - see. Removal and installation the oil pan — Removal, - after disconnecting the electrical wiring from the oil level sensor, release the retainer and push the sensor into the pan.

2. Remove the bolts securing the lower pan section to the main cast section. Remove the lower section and its sealing gasket, being careful not to damage the sensor wiring.

3. To remove the main section of the sump, you must first remove the oil filter (see Chapter Routine maintenance).

It would be wise to replace the filter when installing it.

4. On models with manual transmission, disconnect the right drive shaft from the transmission (see Chapter Clutch and drive shafts). To ensure adequate access, remove the right shaft bearing flange from the gearbox housing.

5. Unscrew the bolts securing the oil pan mounting flange to the transmission housing.

6. Unscrew the bolts securing the oil intake to the main bearing cap bridge and to the oil pump.

7. Using several steps, evenly loosen and then remove the bolts of the main section of the oil pan to the cylinder block/oil pump. If the pan is "stuck" and does not give in, lightly tap it on the sides with a soft-faced hammer. Lower the pan and remove it from under the car, complete with the oil intake. Remove and discard the sealing gasket - the gasket must be replaced during assembly.

Installation

The pan mounting bolts must be replaced without fail.

1. Thoroughly clean the mating surfaces of the pan, oil intake and block, completely removing traces of dirt and oil from them. Clean the threaded holes in the pan from traces of old anaerobic sealant.



2. Replace the oil pickup sealing ring.

3. Make sure that the mating surfaces of the main section of the sump and the cylinder block are absolutely clean and dry, remove traces of anaerobic sealant from the threaded portion of the mounting bolts.

4. Apply a bead of sealant to the mating surface of the cylinder block around the oil pump housing and rear main bearing cap.

5. Place a new gasket on the main pan section and apply a few drops of anaerobic sealant to the threaded portion of the mounting bolts.

6. Press the pan assembly with the oil pickup and sealing gasket to the block and tighten the mounting bolts. Moving from the center to the edges in a diagonal sequence, gradually tighten the casting mounting bolts to the required force. Also tighten the oil pickup mounting bolts to the required force.

7. Tighten the bolts securing the main section flange of the oil pan to the transmission housing to the required torque.

8. Install the exhaust pipe (see Chapter Power and exhaust systems). Install the drive shaft bearing flange.

9. Install the drive shaft (see Chapter Clutch and drive shafts).

10. Make sure that the mating surfaces of the lower and main sections of the pan are absolutely clean and dry, place a new gasket on the lower section and press the assembly onto the main assembly - do not forget to install a new sealing ring on the oil level sensor connector and seat the connector into the main section of the pan.

11. Tighten the new bolts to secure the bathtub tray, then tighten the bolts to stage 1 torque moving diagonally from the center to the edges. Then tighten the fasteners to stage 2 torque in the same order to the corner.



12. Install a new oil filter.

13. Connect the wiring to the oil level sensor.

14. Lower the vehicle and add fresh engine oil (see Chapter Routine maintenance).