Attention! Two types of pallets are installed on the described engines. Early models have a one-piece stamped steel pan, while later models have a two-piece pan, where a smaller section, also made of stamped steel, is attached to the base of the main section, which is cast aluminum alloy.
One piece pallet
Attention! Installation will require a new reflector plate (pan gasket built into it).
Removing
1. Disconnect the negative cable from the battery.
Attention! On models with anti-theft system Opel (ATWS), the negative wire must be separated from the battery terminal within 15 seconds after the ignition is turned off, otherwise the alarm will sound.
2. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Loosen the mounting screws and remove the lower engine cover.
3. Drain engine oil (see related section), then install a new sealing washer and tighten the drain plug with the tightening torque specified specifications.
4. Where available, disconnect the electrical wiring connector from the oil level sensor on the sump.
5. Loosen and remove the bolts securing the tie-down brackets to the transmission case and cylinder block walls. Remove both brackets from the engine, then remove the lower flywheel cover from the transmission case base.
6. Loosen and remove the nuts securing the left and right engine mount brackets to the rubber pad blocks. Unscrew the bolts of the right suspension bracket and remove it from the cylinder block.
7. Hook the winch to the cylinder head mounting lugs, then lift the engine up to transfer its weight onto the winch.
8. Gradually loosen and remove the bolts securing the sump to the cylinder block base/oil pump. Tap the pan with your palm, carefully separate it and remove it from under the car. Raise the engine slightly to get the clearance required to remove the sump. Take care not to stress the wiring/engine hoses or bend the exhaust system.
9. Turn off bolts of fastening and remove a reception tube/mesh filter of the oil pump from the basis of a casing of the pump, having paid attention to ring consolidation. Remove the reflector plate assembly.
10. Check oil pump suction pipe/strainer for clogging and cracks and replace/clean components as needed.
Attention! If the pan will not be 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 contact surfaces of the sump, cylinder block and oil pump casing. Also remove all traces of blocking compound from the suction tube/pump strainer bolt threads and sump bolts.
12. Apply a small amount of suitable sealant (Opel recommends compound 15 03 295) on the areas of the contact surface of the cylinder block around the joints of the casing of the oil pump and the cover of the rear main bearing.
13. Install a new O-ring on the downpipe/oil pump strainer and apply a few drops of blocking compound (Opel recommends compound 15 10 181) on the thread of the bolts of the mesh oil receiver.
14. Place a new reflector plate in working position, then install a mesh oil receiver and tighten the fastening bolts with the tightening force regulated by the Specifications.
15. Apply a small amount of blocking compound to each of the sump mounting bolts, then install the sump onto the crankcase. Insert the fastening bolts and gradually tighten them with the tightening torque specified in the Specifications, moving from the center in a diagonal sequence.
16. Install the suspension bracket on the cylinder block and tighten the fastening bolts with a tightening force regulated specifications. Lower the rear of the engine onto rubber mounts. Unhook the winch from the engine, then install the mounting nuts and tighten them with a tightening torque regulated specifications.
17. Install lower flywheel cover to transmission case, then install tie down brackets. Screw in the bolts securing the brackets to the cylinder block and transmission housing, and tighten them with a tightening torque regulated specifications.
18. Connect the oil level sensor wiring connector (where available).
19. Install the engine undershield, then lower the vehicle to the ground and fill the engine with fresh oil (see related section).
Two-section pallet
Attention! Installation will require new pan bolts and sub-frame mounting bolts, as well as new central tie rod mounting nuts.
Removing
20. Follow the steps described in points 1-3.
21. On models with Xenon headlights (see related section) Disconnect the wiring harness connector from the vehicle's front pitch sensor, then unfasten the linkage from the ball joint of the sensor arm.
22. Remove the central steering rod (see related section).
23. Loosen and remove the nuts securing the left and right engine mounts to the subframe.
24. Hook the winch to the cylinder head mounting lugs and lift the engine to transfer its weight onto the winch. Alternatively, use a special frame that is installed across the engine compartment.
25. Unscrew the bolts of the front fastening of the sub-frame approximately 4 turns (see related section). Support the rear of the subframe with a jack, then loosen and remove the rear suspension bolts. Lower the rear of the frame approximately 10 cm to gain access to the sump.
26. If there is an oil level sensor, disconnect the connector of its electrical wiring on the left side of the main section of the sump, then pull out the mounting bracket and push the connector into the sump.
27. Loosen and remove the bolts securing the smaller pan section to the main pan, then remove the smaller pan section along with the gasket. On models with an oil level transmitter, be careful not to damage the sensor wiring.
28. To remove the main section from the engine, disconnect the oil temperature sensor harness connector (where available), then loosen and remove the bolts securing the muffler exhaust pipe bracket.
29. Remove 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 vehicle. Remove the gasket - it must be replaced.
Attention! If the sump sections will not be installed immediately, raise the subframe to operating position and install the mounting bolts, then lower the rear of the engine onto the frame.
30. Inspect the oil pump suction pipe/strainer for clogging and cracks. If necessary, unscrew the intake tube/strainer bolts and remove them from the base of the pump casing along with the O-ring. Clean the oil strainer in solvent or replace it.
Installation
31. Clean dirt and oil from the contact surfaces of the small section of the sump, its main section, the cylinder block and, if removed, the oil strainer and the oil pump casing. Also remove all traces of blocking compound from the main section 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 oil strainer assembly. Apply fresh blocking compound (Opel recommends compound 15 10 181) on the thread of the fastening bolts, then insert the bolts and tighten them with the tightening force regulated by 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 on the main sump section, then apply some blocking compound to the threads of the section-to-cylinder block/oil pump bolts. Bring the section into working position, being careful not to displace the gasket, then insert, but do not tighten, all mounting bolts and install the muffler exhaust pipe bracket.
35. Moving from the center in a diagonal sequence, gradually tighten the bolts securing the main section to the cylinder block / oil pump with the tightening torque regulated by the Specifications.
36. Tighten the bolts securing the main section flange to the transmission case to the specified torque, then securely tighten the exhaust bracket bolts. Where necessary, connect an oil temperature sensor.
37. Ensure that the contact surfaces of the small section of the sump and its main section are clean and dry, place a new gasket on the small section and install it in 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. Attach the connector with a bracket.
38. Insert new bolts securing the small section of the pallet, then, working in a diagonal sequence, tighten them with a torque (see specs). 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 the operating position so that the protrusions of the engine mount fit into the slots in the frame. Install four new rear mounting bolts, then remove the front subframe mounting bolts and install new ones. Tighten the frame mounting bolts with a tightening torque specified specifications and turn to the right angles (see related section).
41. Unhook the winch from the engine, then install the nuts that secure the engine hangers to the subframe, and tighten them with a tightening torque regulated specifications.
42. Install the central tie rod (see related section).
43. On models with Xenon headlights, attach the linkage ball joint to the vehicle's pitch sensor and connect the electrical harness connector (see related section).
44. Install the engine undershield, then lower the vehicle to the ground and fill the engine with fresh oil (see related section).
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