Note: When installing the pan, replace the gaskets, and use sealant on the oil pump and rear main bearing.
Removing
1. If the engine is in the car, proceed as described below, otherwise go to step 9.
2. Disconnect the negative cable from the battery.
3. Drain the engine oil according to Section 1, then install and tighten the drain plug.
4. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands.
5. Remove the front section of the exhaust system as described in Section 4C.
6. Where applicable, disconnect wiring from oil level sensor.
7. Unscrew the mounting bolts and remove the engine locking plate to the transmission from the clutch housing.
8. Turn off bolts of fastening, remove the pallet. Note that on most models the sump deflector can be moved far away from the cylinder block along with the sump, but cannot be removed until the oil pump pickup pipe is removed.
9. On models 1.6, 1.8 and 2.0 liters, in order to remove the pan deflector, it is necessary to unscrew the bracket that secures the oil pump intake pipe to the cylinder block. The deflector can then be removed through the receiving tube. On models C16NZ2, 1.8 and 2.0 liters, remove the rubber gasket from the pan deflector with a screwdriver.
10. If required, the oil pump pickup tube can be removed by unscrewing one bolt securing the bracket to the cylinder block. Then unscrew the two bolts securing the end of the pipe to the oil pump. Remove the O-ring.
11. Clean the mating surfaces of the cylinder block, deflector (where applicable) and a pallet from the old gasket and sealant.
Installation
12. Apply sealant (Opel #90485251 or equivalent) to the connection between the oil pump and the cylinder block, and between the rear main bearing cap and the cylinder block (see illustrations).
13. On models C16 NZ2, 1.8-2.0 liters, place a new rubber gasket on the flange of the pan deflector; make sure it is placed correctly (see illustration).
14. On 1.6, 1.8 and 2.0 liter models, install the sump deflector in the cylinder block, positioning it through the oil pump intake tube.
15. If the pickup tube has been removed, install it on the oil pump using a new O-ring and tighten the bolts to the specified torque specifications (see illustrations).
16. Where applicable, install the bracket that secures the pickup tube to the cylinder block; make sure that it passes through the corresponding hole in the deflector under the bottom, if any (see illustration).
17. Coat the pan bolts with thread blocking compound (Opel №90167347), then install under the bottom, and tighten the bolts with a tightening torque regulated specifications (see illustrations).
18. If the engine is in the car, further installation is carried out in the reverse order of removal. Then install the front section of the exhaust system, guided by Section 4C. Finally, fill the engine with oil as described in Section 1.
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