Contents: Removal ⬇ Installation ⬇
Removal
The oil pan can be removed without removing the engine, if, for example, it is necessary to replace the crankcase gasket. The work is quite labor-intensive, since it is necessary to lower the entire front axle beam in order to remove the oil pan. The relevant works are described in Chapter Suspension and steering. In addition, the engine must be lifted with some kind of lifting device to detach the mounts.
1. Remove the bottom protective sheet (oil pan shield) under the front of the car.
2. Place a container under the oil pan and remove the drain plug from the crankcase. The engine oil should be warm, but not hot.
3. Remove the suspension cross member located under the oil pan.
4. Lower the front axle as described in the relevant section.
5. Loosen the bolts and remove the clutch slave cylinder (see chapter Clutch).
6. Loosen the bracket mounting bolts and remove them from the gearbox and cylinder block. The engine must be secured to a lifting mechanism (for example, on a hoist or on a hand crane). For DOHC engines, remove the engine mounts between the transmission and cylinder block.
7. According to the illustration. remove the oil line (1) by disconnecting the holder (2). Also remove the oil baffle sheet. For a DOHC engine, the fastening of the parts in question corresponds to the right side of the illustration. Left – for 2.0 l engine.
Installation
The installation of the oil pan is performed in the reverse order of its removal:
1. Thoroughly clean the mating surface of the cylinder block and apply a small amount of sealant to the corners of the block. On the left in the illustration. application of sealant is shown for the oil pump, on the right for the bearing cover (until the end of 1996).
2. Install the oil deflector sheet onto the new gasket. If the oil deflector sheet is replaced, it must be borne in mind that it is installed with a new vulcanized gasket.
3. Attach the oil line to the oil pump and secure it with a clamp. Lubricate the bolts with Loctite. The threaded holes can be tapped to remove any old Loctite. Tighten the inlet pipe mounting bolts to 8 Nm and the clamp mounting screw to 6 Nm.
4. Install the oil pan with a new gasket onto the cylinder block. Screw in the mounting bolts using sealant. Find out what sealant is used for this in Opel workshops. Installation must be completed within 10 minutes. The threaded holes in the cylinder block can be passed with a tap to remove the remains of the old sealant. Tighten the bolts to 15 Nm.
5. Install the engine mounts, clutch slave cylinder, crossmember and oil pan shield in the reverse order of removal. The tightening moments are equal.
6. At the end of the assembly, screw into the oil pan and tighten the drain plug (55 Nm). Fill the engine with oil.
7. Start the engine and check the tightness of the oil pan connection.
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