Contents: Solid pallet ⬇ Two-section pallet ⬇
Attention! The engines described are equipped with two types of oil pans. Early models are equipped with a single pan made of stamped steel, while later models are equipped with a two-section pan, where the smaller section, also made of stamped steel, is attached to the base of the main section, which is cast from an aluminum alloy.
Solid pallet
Attention! A new reflector plate will be required for installation (the pan gasket is built into it).
Removal
1. Disconnect the negative cable from the battery.
Caution! On models with Opel Anti-Theft System (ATWS), the negative cable must be disconnected from the battery terminal within 15 seconds after the ignition is turned off, otherwise the alarm will be triggered.
2. Apply the handbrake, then jack up the front of the car and place it on axle stands. Loosen the mounting screws and remove the lower engine shield.
3. Drain the engine oil (see the relevant section), then install a new sealing washer and tighten the drain plug to the specified tightening torque Specifications.
4. Where available, disconnect the electrical connector from the oil level sensor on the pan.
5. Loosen and remove the bolts securing the tie rods to the transmission case and cylinder block walls. Remove both brackets from the engine, then remove the lower flywheel cover from the base of the transmission case.
6. Loosen and remove the nuts securing the left and right engine mount brackets to the rubber mount blocks. Unscrew the bolts of the right mount bracket and remove it from the cylinder block.
7. Attach a winch to the cylinder head mounting eyes, then lift the engine to transfer its weight to the winch.
8. Gradually loosen and remove the bolts securing the oil pan to the engine block base/oil pump. Tap the oil pan with the palm of your hand, gently pry it loose and remove it from underneath the vehicle. Raise the engine slightly to provide clearance for removing the oil pan. Be careful not to strain any engine wiring/hoses or bend the exhaust system.
9. Loosen the mounting bolts and remove the oil pump intake tube/strainer from the base of the pump housing, paying attention to the O-ring. Remove the deflector plate assembly.
10. Check the oil pump suction tube/screen for clogging and cracks and replace/clean components as necessary.
Caution: If the pan is not installed immediately, install the suspension bracket on the cylinder block and lower the engine onto the rubber suspension pads.
Installation
11. Clean dirt and oil from the mating surfaces of the oil pan, cylinder block and oil pump housing. Also remove all traces of locking compound from the threads of the pickup tube/pump strainer bolts and the oil pan bolts.
12. Apply a small amount of suitable sealant (Opel recommends using composition 15 03 295) on the areas of the contact surface of the cylinder block around the joints of the oil pump casing and the rear main bearing cover.
13. Install a new O-ring on the oil pump intake tube/strainer and apply a few drops of blocking compound (Opel recommends using composition 15 10 181) on the threads of the bolts securing the mesh oil receiver.
14. Place the new deflector plate in position, then install the strainer and tighten the mounting bolts to the torque specified in the Specifications.
15. Apply a small amount of locking compound to each of the oil pan mounting bolts, then install the oil pan onto the crankcase. Insert the mounting bolts and tighten them gradually to the torque specified in the Specifications, working from the center in a diagonal sequence.
16. Install the suspension bracket on the cylinder block and tighten the mounting bolts with the specified tightening force Specifications. Lower the rear of the engine onto the rubber suspension pads. Unhook the winch from the engine, then install the mounting nuts and tighten them to the specified torque Specifications.
17. Install the lower flywheel cover onto the transmission case, then install the tie rods. Screw in the bolts securing the brackets to the cylinder block and transmission case and tighten them to the specified tightening torque Specifications.
18. Connect the oil level sensor wiring connector (where is available).
19. Install the engine lower shield, then lower the car to the ground and fill the engine with fresh oil (see the relevant section).
Two-section pallet
Caution: Installation will require new oil pan mounting bolts, engine subframe mounting bolts, and new center tie rod mounting nuts.
Removal
20. Follow the steps described in points 1-3.
21. On models with Xenon headlights (see the relevant section) disconnect the wiring harness connector from the front roll sensor, then disconnect the link from the sensor arm ball joint.
22. Remove the central steering rod (see the relevant section).
23. Loosen and remove the nuts securing the left and right engine mounts to the engine subframe.
24. Attach a winch to the cylinder head mounting eyes and lift the engine to transfer its weight to the winch. Alternatively, use a special stand installed across the engine bay.
25. Loosen the front subframe mounting bolts approximately 4 turns (see the relevant section). Support the rear of the subframe with a jack, then loosen and remove the rear hanger bolts. Lower the rear of the frame approximately 10 cm to gain access to the pan.
26. If equipped with an oil level sensor, disconnect its wiring connector on the left side of the main pan section, then pull out the retaining bracket and push the connector into the pan.
27. Loosen and remove the bolts securing the smaller pan section to the main pan, then remove the smaller section along with the gasket. On models with an oil level sensor, be careful not to damage the sensor wiring.
28. To remove the main section from the engine, disconnect the oil temperature sensor wiring connector (where is available), then loosen and remove the bolts securing the muffler inlet pipe bracket.
29. Loosen the bolts securing the main section flange to the transmission case, then gradually loosen and remove the bolts securing it to the cylinder block base/oil pump. Tap the main section with the palm of your hand, then lower it away from the engine and remove it from under the car. Remove the gasket - it must be replaced.
Caution: If the pan sections are not installed immediately, raise the engine subframe into position and install the mounting bolts, then lower the rear of the engine onto the subframe.
30. Inspect the oil pump pickup tube/strainer for clogging and cracks. If necessary, remove the pickup tube/strainer bolts and remove them from the base of the pump housing along with the O-ring. Clean the oil pickup screen in solvent or replace it.
Installation
31. Clean dirt and oil from the mating surfaces of the small pan section, the main pan section, the cylinder block and, if removed, the oil strainer and oil pump housing. Also remove all traces of blocking compound from the main pan mounting bolts and the pickup tube/strainer bolts.
32. Where necessary, place a new O-ring on the oil pump pickup tube and install the strainer assembly. Apply fresh blocking compound (Opel recommends using composition 15 10 181) onto the threads of the mounting bolts, then insert the bolts and tighten them to the tightening torque specified in the Specifications.
33. Apply a small amount of suitable sealant (Opel recommends sealant 15 03 295) on the areas of the contact surface of the cylinder block around the joints of the oil pump casing with the rear main bearing cover.
34. Install a new gasket onto the main pan section, then apply a small amount of locking compound to the threads of the section to block/oil pump mounting bolts. Move the section into position, being careful not to dislodge the gasket, then insert but do not tighten all mounting bolts and install the exhaust downpipe bracket.
35. Working from the centre in a diagonal sequence, gradually tighten the main section bolts to the cylinder block/oil pump to the tightening torque specified in the Specifications.
36. Tighten the bolts securing the main section flange to the transmission case to the torque specified in Specifications, then tighten the exhaust bracket bolts securely. Connect the oil temperature sensor where necessary.
37. Make sure that the mating surfaces of the small pan section and its main section are clean and dry, place a new gasket on the small section and install it in its working position. On models with an oil level sensor, first install a new O-ring on the wiring connector and insert the connector into the main section. Secure the connector with a clamp.
38. Insert the new small pan section mounting bolts, then, working in a diagonal sequence, tighten them to the specified tightening torque (see Specifications). In the same sequence, tighten the bolts to the desired angle. It is recommended to use an angle template for this to ensure accuracy.
39. Connect the oil level sensor wiring connector (where necessary).
40. Raise the subframe to its operating position so that the engine mount tabs fit into the frame slots. Install the four new rear mounting bolts, then remove the front subframe mounting bolts and install new ones. Tighten the subframe mounting bolts to the specified torque Specifications and turn it to the required angles (see the relevant section).
41. Unhook the winch from the engine, then install the nuts securing the engine hangers to the subframe and tighten them to the specified tightening torque Specifications.
42. Install the center steering rod (see the relevant section).
43. On models with Xenon headlights, attach the tie rod ball joint to the vehicle pitch sensor and connect the wiring harness connector (see the relevant section).
44. Install the engine undershield, then lower the vehicle to the ground and fill the engine with fresh oil (see the relevant section).
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