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Vauxhall Workshop Service and Repair Manuals

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Replace oil baffle plate > < Oil Pan, Remove and Install

Astra H

Replace oil separator

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Raise vehicle by its full height
4.   Remove lower engine compartment cover and/or right-hand engine splash guard
5.   Place collecting basin underneath.
6.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


7.   Detach 2x coolant hoses (1) from heat exchanger
•   Undo 2 clamps
Object Number: 7361571 Size: DEFAULT


8.   Lower vehicle by its full height
9.   Remove engine cover
10.   Remove battery
•   Detach positive terminal (3) from positive pole
– Slacken nut
•   Remove bracket 1)
– Unscrew bolt (2)
Object Number: 7360933 Size: DEFAULT


11.   Remove battery support.
•   Remove pre-glow system control unit (4)
•   Remove wiring harness plug (3)
•   Unclip coolant hose bracket
•   Detach wiring harness
– Undo cable tie (1)
– Unclip 2x brackets
•   Unscrew 3x bolts (2)
Object Number: 3446570 Size: DEFAULT


12.   Remove cowl trim seal (1)
13.   Remove windscreen wiper arms (2)
•   Remove 2x covering caps
•   Unscrew 2x nuts
•   Remove 2x washers
•   Pull 2x windscreen wiper arms from shaft
Object Number: 3446487 Size: DEFAULT


Object Number: 3446486 Size: DEFAULT

14.   Detach cowl trim (1)
Important:   Carefully release clips from upper bulkhead bracket from the inside
•   Lift cowl trim in vicinity of bulkhead
•   Unclip 5x clips (3)
•   Detach windscreen washer system hose (2)

15.   Detach engine vent hose (2)
•   Undo 2 clamps
•   Unclip from bracket (1)
Object Number: 7361574 Size: DEFAULT


16.   Remove vacuum line (1)
•   Detach 4x vacuum hoses
Note:   Mark vacuum hoses
•   Unscrew 3 bolts
Object Number: 7361575 Size: DEFAULT


17.   Disconnect 2x wiring harness plugs
•   Disconnect wiring harness plug for fuel preheating
•   Disconnect wiring harness of fluid level indicator
18.   Place collecting basin underneath.
19.   Detach fuel supply lines from fuel filter housing
•   Disconnect 2x fuel lines with KM-796-A
Note:   Seal fuel lines with KM-807 , KM-6015 or KM-6320
20.   Detach fuel filter housing from crash box
21.   Remove crash box
•   Unclip 2x wiring harnesses
•   Unclip wiring harness plug
•   Detach solenoid valve
– Unscrew nut
•   Remove retaining plate
– Unscrew 2x nuts
22.   Remove coolant pipe (2)
•   Unclip 2x coolant hoses from bracket (4)
•   Undo bracket (3)
– Unscrew 2x nuts
•   Undo bracket (1)
– Unscrew nut
•   Detach 2x coolant hoses
– From thermostat housing
– From coolant pipe
– Undo 2 clamps
Note:   Remove coolant pipe at intake pipe upwards
Object Number: 7361576 Size: DEFAULT


23.   Remove oil separator/vacuum reservoir bracket (1)
•   Undo 2 clamps
•   Detach engine vent hose
– Quick-release fitting
•   Unclip wiring harness bracket
•   Unscrew 3 bolts
•   Unscrew 2x nuts
Object Number: 7361578 Size: DEFAULT


24.   Detach oil separator (2) from bracket
•   Unscrew 3x bolts (1) and (arrow)
Object Number: 7361579 Size: DEFAULT


  Install

25.   Attach oil separator to bracket
•   Tighten 3x bolts
26.   Install oil separator/vacuum reservoir bracket
•   Tighten 3x bolts
– Tighten 2x nuts
•   Attach 2x clamps
•   Connect engine vent hose
– Quick-release fitting
•   Clip in wiring harness cover
27.   Install coolant pipe
•   Attach 2x coolant hoses
– To thermostat housing
– To coolant pipe
– Attach 2x clamps
•   Clip 2x coolant hoses into bracket
•   Tighten 3x nut 9 Nm
28.   Install crash box
•   Insert retaining plate
– Tighten 2x nuts
•   Attach solenoid valve
– Tighten nut
•   Clip in wiring harness plug
•   Clip in 2x wiring harnesses
29.   Install fuel filter housing in crash box
30.   Attach fuel supply lines to fuel filter housing
Important:   The fuel lines must engage audibly
•   Connect 2x fuel lines
31.   Connect 2x wiring harness plugs
•   Connect wiring harness plug for fuel preheating
•   Connect wiring harness for fluid level indicator
32.   Attach vacuum line
•   Connect 4x vacuum hoses
Note:   Pay attention to marks
•   Tighten 3x bolt 9 Nm
33.   Attach engine venting hose
•   Attach 2x clamps
•   Clip into bracket
34.   Fit cowl trim
•   Attach windscreen washer system hose
•   Clip in 5x clips
35.   Install 2x windscreen wiper arms
•   Insert 2x washers
•   Tighten 2x nuts
•   Install 2x covering caps
36.   Remove cowl trim seal
37.   Install battery holder
•   Tighten 3x bolts
•   Attach wiring harness
– Connect cable ties
– Clip on 2x brackets
•   Attach pre-glow system control device
•   Attach wiring harness plug
•   Clip on coolant hose bracket
38.   Install battery
•   Install bracket
– Tighten bolt
•   Insert battery insulation
•   Attach positive connection to positive terminal
– Tighten nut
•   Attach positive cable to positive terminal
– Tighten bolt
39.   Install engine cover
40.   Raise vehicle by its full height
41.   Attach 2x coolant hoses to heat exchanger
•   Attach 2x clamps
42.   Install lower engine cover and right engine splash guard
43.   Lower vehicle by its full height
44.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
45.   Top up coolant or ensure correct quantity is present. LUREF_1.gif
46.   Program volatile memories
47.   Close bonnet

Replace oil baffle plate > < Oil Pan, Remove and Install