Removing
Raise the vehicle and place it on stands.
Remove the front exhaust pipe.
Drain the engine oil and tighten the drain plug.
Disconnect the wire from the oil level sensor (if there).
Loosen the cover bolts on the gearbox.
Loosen all screws securing the crankcase and remove it.
Remove the oil pickup brackets.
Remove tube.
Installation
Remove any gasket residue from the oil pan mating surface.
Tighten the oil intake bolts: for engines with a volume of 1.4 and 1.6 l - to a torque of 8 Nm, for engines of 1.8 and 2.0 l - to a torque of 6 Nm.
Cover the mating surface with a layer of sealant, e.g. Opel 503294 (9000181) (see arrows in Fig. A9248).
Put on a new gasket.
Coat the sealing surfaces on the roundings with sealant.
Install the oil sump and tighten its bolts: for engines with a volume of 1.4 and 1.6 liters - a torque of 8 Nm, for engines with a volume of 1.7, 1.8 and 2.0 liters - 5 Nm.
Attention! Do not overtighten the bolts, otherwise the gasket may be squeezed out. Lubricate the bolts with sealant before tightening, for example, Opel 1503177.
Install the gearbox cover.
Tighten bolts for front exhaust pipe to 25 Nm.
Connect the connector to the oil level sensor.
Fill with oil.
After a test drive, check for leaks at the connections and at the drain plug. Tighten screws if necessary.
TC4EE1 1.7L turbocharged diesel engine
Removing
Loosen all bolts securing the lower part of the oil sump.
Unscrew all bolts securing the upper part of the crankcase and remove the crankcase.
Installation
Remove any remaining gasket from the crankcase mating surface.
Coat the mating surface with Opel sealant 1503294.
Tighten the crankcase top bolts to 10 Nm.
Tighten the lower crankcase bolts to 10 Nm.
Fit the front exhaust pipe and tighten it to the turbocharger to 65 Nm.
Install a new oil drain plug gasket and tighten the plug to 80 Nm.
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