Z16XEP engine
1. Remove the dipstick for measuring the engine oil level, unscrew the fixing bolt of the lifting eye and remove the eye, remove the engine oil meter tube.
2. Raise the car on a lift and remove the right engine boot (see Section 5).
3. Disconnect the cable channels of the lambda probe (see illustration 11.6).
4. Loosen the rear muffler retainer, release the muffler from the two holders and, with the help of an assistant, remove it (see resist. illustration).
5. Disconnect the exhaust pipe from the catalytic converter (see illustration 11.7).
6. Remove the exhaust pipe by disconnecting it from the front muffler (see resist. illustration).
7. Drain the engine oil from the crankcase (see Chapter 1, Section 6) and disconnect the electrical wiring connector of the engine oil level sensor.
8. Remove 2 rubber plugs, remove 3 sump to transmission bolts, then 15 sump bolts (see resist. illustration) and, using a suitable tool, pry and disconnect the oil pan.
9. Before installing the pallet, clean all mating surfaces of sealant residues and pre-drill the threads of 15 holes with a tap.
10. Apply a bead of sealant (gray color) 2-3 mm thick on the surfaces indicated on the resist. illustration, and put the tray back in place.
Attention: Installation must be completed no later than 10 minutes after applying the sealant.
11. Install the remaining components in the reverse order of their removal.
Z18XE engine
12. Disconnect the electrical wiring connectors of the precatalytic lambda probe and the engine oil level sensor (see resist. illustration).
13. Raise the car on a lift, remove the exhaust system (see chapter 4).
14. Drain the engine oil from the crankcase (see Chapter 1, Section 6). Before screwing in the drain plug, be sure to replace the gasket.
15. Remove the 2 rubber plugs and unscrew the ones indicated on the resist. illustration fixing bolts and 12 bolts of fastening of the oil pan. Using a suitable tool, pry and disconnect the oil pan.
16. Before installing the pallet, clean all mating surfaces of sealant residues and pre-thread all holes.
17. Apply a bead of sealant (gray color) 2.5-3.5 mm thick on the surfaces indicated on the resist. illustrations and put the tray back in place.
Attention: Installation must be completed no later than 10 minutes after applying the sealant.
18. Installation of other components is made in an order, the return to an order of their removal.
Z20LE engines (L/R/H)
19. Remove the crankcase protection (see Section 5) and disconnect the electrical wiring connector of the lambda probe of the catalytic converter.
20 Remove the front exhaust pipe of the exhaust system and drain the engine oil from the crankcase (see Chapter 1, Section 6).
21. Disconnect the wiring of the engine oil level sensor and remove the retaining ring, then unscrew the mounting bolts of the lower part of the oil pan and remove it (see resist. illustration).
22. Loosen the nuts and remove the turbocharger oil supply line (see resist. illustration).
23. Using the KM-726-A tool, remove the oil pump oil filter.
24. Turn out bolts of fastening of the top part of the pallet to transmission assembly (see resist. illustration), separate the sump from the engine block and remove the oil pump (see Section 13).
25. Disconnect the oil intake tube from the balancing shaft block (see resist. illustration).
26. Move the upper part of the pallet in the direction indicated on the Ref. arrow, unscrew the 2 fixing bolts and remove the upper part of the oil pan together with the oil intake tube.
27. Before installing the pallet, clean all mating surfaces from sealant residues and old gaskets. Install all removed components in the reverse order of their removal, do not forget to replace all gaskets. Before installing the upper part of the oil pan, apply sealant (black color) at specified points (see resist. illustration) and lubricate the threads of its mounting bolts with sealant (Green colour).
Z14XEP engine
28. Raise the car on a lift and disconnect the connector of the electrical wiring of the lambda probe of the catalytic converter (see resist. illustration).
29. Loosen the rear muffler retainer, release the muffler from the two holders and, with the help of an assistant, remove it (see illustration 12.4).
30. Loosen the 3 fixing nuts and disconnect the front exhaust pipe from the catalytic converter (see resist. illustration).
31. Remove the exhaust pipe by disconnecting it from the front muffler (see illustration 12.6).
32. Remove the right engine boot (see Section 5) and drain the engine oil from the crankcase.
33. Turn out 3. bolts of fastening of the pallet to transmission, and then 16 more bolts of fastening to the engine block (see resist. illustration) and remove the tray.
34. Before installing the pallet, clean all mating surfaces from the remnants of old gaskets. Install all removed components in the reverse order of their removal, do not forget to replace all gaskets. When installing the pallet, tighten all 19 fixing bolts of the pallet by hand, and then tighten them with the required force.
Z17DTL/H engines
35. Disconnect the wire from the negative terminal of the battery, remove the dipstick for measuring the oil level, raise the car on a lift and remove the engine crankcase protection (see Section 5).
36. Drain the engine oil from the oil pan (see Chapter 1, Section 6), Be sure to replace the sealing washer on the drain plug.
37. Remove the bottom of the pallet (see resist. illustration), by removing 15 fixing screws.
38. Remove the front exhaust pipe by disconnecting it from the front catalytic converter and from the front muffler (see resist. illustration).
39. Having unscrewed 2 bolts, disconnect the dipstick tube for measuring the engine oil level from the top of the sump (see resist. illustration).
40. Disconnect the wiring connector of the engine oil level sensor (see resist. illustration).
41. Turn out the indicated on the resist. illustrations of the fastening elements of the upper part of the oil pan and, using a suitable tool (for example with a spatula), separate the sump from the engine block.
42. Before installing the pallet, clean all mating surfaces from the remnants of old gaskets. Install all removed components in the reverse order of their removal, do not forget to replace all gaskets. The top and bottom of the pallet is installed on the sealant (gray color).
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