Engine Oil Cooler — Removal and Installation (Opel Omega B2)

Removal

1. Drain the cooling system (see the relevant section).

2. Remove the intake manifold together with the flange (see the relevant section).

3. Disconnect the wiring connectors from the coolant temperature gauge sensor and the engine management system temperature sensor, which are screwed into the cooling system outlet pipes (see illustration).



4. Loosen the clamps and separate the cooling system hoses from the cylinder head pipes (see illustration).



5. Unscrew the mounting bolts and remove the cooling system outlet pipes from the cylinder heads. Remove the O-rings and discard them - they are subject to replacement (see illustration).



6. Loosen the mounting bolts and remove the upper thermal insulation from the left cylinder head exhaust manifold. To make it easier to access the rear bolt, remove the front section of the exhaust system (see the relevant section).



7. Place a suitable container under the oil filter. Unscrew the filter, using a special tool if necessary, and drain the oil into the container. If the filter was damaged or deformed during removal, replace it.

8. Remove the union nuts securing the coolant pipes to the cylinder block, then remove the banjo bolts securing the pipes to the cooler. Remove the sealing washers from each side of the unions and move the pipes away from the cooler (see illustrations).





9. Remove the large nuts securing the cooler connectors to the cover, then remove the mounting bolts and remove the cover from the top of the cylinder block (see illustrations). Remove the gasket (where is available) - it is subject to replacement. When installing a new gasket, a sealant will be required.







10. Lift the cooler and remove it from the engine, keeping it vertical to avoid spilling oil (see illustration). Remove the O-rings from the couplings and discard them - they must be replaced.



11. If the cooler is damaged, replace it.

Installation

12. Make sure that the contact surfaces of the cooler, cover and cylinder block are clean and dry.



(Original posted on the website www.OpelBook.ru)

13. Place new O-rings on the cooler couplings, then install the cover and tighten the large nuts.

14. Apply a bead of suitable sealant (Opel recommends using composition 15 03 296) approximately 2mm thick into the groove on the cooler cover (see illustration).



15. Install the cooler assembly on the cylinder block and tighten the cover mounting bolts evenly and gradually with the specified tightening force Specifications. Then tighten the cooler nuts to the specified tightening torque (see illustration).



16. Bring the cooler tubes into position and screw their union nuts into the cylinder block a few turns. Place new sealing washers on each side of the unions, then install the banjo bolts. Tighten the banjo bolts to the specified torque Specifications, then tighten the nuts of the connecting sleeves (see Specifications).



17. Place new O-rings on the coolant outlet pipes, then install the pipes on the cylinder heads and tighten the mounting bolts to the specified tightening torque Specifications. Connect the hoses to the pipes and secure them with clamps, then connect the sensor connectors.

18. Install the intake manifold (see the relevant section), then place the exhaust manifold insulation and (where removed) the front exhaust pipe in the working position.

19. Install a new oil filter and fill the cooling system (see the relevant section).

20. Finally, check the engine oil level (see the relevant section).