Removing
Small pallet section
Attention! When installing, you will need new bolts securing the small section of the pallet.
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. Unscrew the mounting screws and remove the lower shield from under the engine.
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. Disconnect the electrical wiring connector from the oil level sensor on the right wall of the main sump section, then pull out the mounting bracket and push the connector into the sump (see illustration).
5. Turn off bolts of fastening of small section of the pallet, then separate it from the main section and remove together with a laying. Be careful not to damage the oil level sensor wiring.
6. If necessary, unscrew the mounting bolts (access to one of them is extremely difficult) and remove the suction pipe/strainer from the base of the oil pump housing along with the O-ring. Check the oil strainer for clogging and damage and replace/clean if necessary.
Main pallet section
Attention! Installation will require new subframe mounting bolts as well as new central tie rod mounting nuts.
7. Remove the small pan section and downpipe/strainer as described in steps 1-6.
8. On models with Xenon headlights, disconnect the wiring connector from the vehicle's front pitch sensor (see related section), then detach the link from the ball joint of the sensor arm.
9. Remove the central tie rod (see related section).
10. Loosen the mounting bolts and remove the vibration dampers from the left and right engine mounts.
11. Loosen and remove the nuts securing the left and right hangers to the subframe.
12. Hook the winch to the engine mounting lugs, then lift it up to take the load off the hangers. Alternatively, use a special frame that mounts across the engine compartment.
13. Unscrew the bolts of the front fastening of the sub-frame (see related section) about 4 turns. Support the rear of the frame with a jack, then loosen and remove the rear suspension bolts. Lower the rear of the subframe approximately 10cm to access the main pan section.
14. Remove the bolts securing the main section flange to the transmission case, then gradually loosen and remove the bolts securing the main section to the cylinder block/oil pump base. Separate the section from the engine by hitting it with the palm of your hand, then remove it from under the vehicle. Remove the seal - it must be replaced.
Attention! If the sump sections are not installed immediately, raise the subframe to operating position and install the mounting bolts, then lower the rear of the engine onto the frame.
Installation
Small pallet section
15. Clean off all dirt and oil from the contact surfaces of the sump sections and the oil strainer/oil pump housing.
16. Where necessary, place a new O-ring on the top of the pickup tube, then install the oil strainer and tighten its mounting bolts to the specified torque specifications (see illustration).
17. Install a new O-ring on the oil level sensor wiring connector.
18. Place a new gasket on the small section of the pan and lift the latter up to the main section. Install the oil level sensor wiring connector in the wall of the main section and fix it with the fixing bracket, then install the small section of the sump on the main section (see illustration).
19. Install new bolts securing the small section of the pallet, then tighten them in a diagonal sequence with the required torque (see specs). Tighten the bolts to the correct angle (see specs). It is recommended to use an angle gauge when doing this to ensure accuracy.
20. Connect the oil level sensor harness connector, then install the engine bottom shield.
21. Lower the car to the ground, then fill the engine with fresh oil (see related section).
Main pallet section
22. Clean off all dirt and oil from the contact surfaces of the main section and cylinder block.
23. Make sure the seal groove of the main section is dry, then apply a bead of sealant to it (Opel recommends compound 15 03 298) (see illustration).
Attention! If Opel sealant is used, the main section must be bolted on within ten minutes of applying the compound.
24. Install a new seal in the groove, then apply a bead of sealant approximately 3 mm wide to the surface of the main section (see illustrations). The sealant should run in the front of the main section along the outside of the seal and in the back along the inside edge of the seal. There should be two strips of sealant on the middle sections of the contact surface of the section.
25. 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 (see illustrations).
26. Bring the main section of the pallet into working position and fasten the bolts of its fastening.
27. Moving from the center in a diagonal sequence, gradually tighten the bolts of the main section to the cylinder block / oil pump with a tightening torque regulated specifications.
28. Tighten the bolts securing the flange of the main section to the transmission housing with a tightening torque regulated specifications.
29. Raise the subframe to the operating position so that the protrusions of the engine mount fit into the corresponding 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, then turn them to the desired angles (see related section).
30. Unhook the winch/special frame from the engine, then install the nuts securing the engine hangers to the subframe, and tighten them with a tightening torque regulated specifications. Install vibration dampers on the hangers and tighten their mounting bolts with the specified tightening torque.
31. Install the central tie rod (see related section).
32. On models with Xenon headlights, attach the linkage ball joint to the vehicle's front pitch sensor and connect the electrical harness connector (see related section).
33. Install the small pan section as described in steps 15-21.
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