Sump Replacement

Make

Vauxhall

Model

Astra J

Section

Engine mechanics - 1.3L Diesel › Repair Instructions - On Vehicle › Sump Replacement

EngineSump Replacement

Oil Pan Replacement Special Tools EN-37228   Separation Tool For equivalent regional tools refer to Special Tools . Removal Procedure 1. Open the hood. 2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement . 4. Remove the catalytic converter. Refer to Catalytic Converter Replacement . 5. Place a drain pan under the oil drain plug.            6. Remove the oil pan drain plug (2) and the oil pan drain plug gasket (3). Caution: Refer to Fastener Caution . 7. Install a NEW oil pan drain plug gasket (3) and the oil pan drain plug (2) and tighten to 20 N·m (15 lb ft) after draining the engine oil. 8. For vehicles with air conditioning, remove the generator and air conditioning compressor belt. Refer to Generator and Air Conditioning Compressor Belt Replacement .            Note:  For vehicles with air conditioning. Air conditioning system remains closed. 9. Remove the 3 air conditioning compressor bolts (1). 10. Remove the air conditioning compressor (2) and hang aside.            11. For vehicles with air conditioning, remove the 4 air conditioning compressor bracket bolts (1). 12. Remove the air conditioning compressor bracket (2).            13. Remove the 4 transmission support brace bolts (2). 14. Remove the transmission support brace (1).            15. Remove the 2 oil pan nuts (1). 16. Remove the 13 oil pan bolts (2).            17. Loosen carefully the oil pan (2) from the lower cylinder block with the EN-37228   separation tool (1).            18. Remove the oil pan (1). Installation Procedure 1. Clean the sealing surfaces.            Note:  The complete installation procedure of the oil pan should be done in 10 minutes. 2. Apply silicone sealing compound (2) to the oil pan sealing surface (1). The thickness of the sealing bead (1) should be 3.0 - 4.0 mm (0.118 - 0.157 in) .            3. Install the oil pan (1).            4. Hand tighten the 2 oil pan nuts (1). 5. Hand tighten the 13 oil pan bolts (2). Caution: Refer to Fastener Caution .            6. Tighten the 13 oil pan bolts and 2 oil pan nuts in sequence as shown:   •  Tighten in first step to 4 N·m (35 lb in) .   •  Tighten in second step to 9 N·m (80 lb in) .            7. Install the transmission support brace (1). 8. Install the 4 transmission support brace bolts (2) and tighten to 30 N·m (22 lb ft) .            9. For vehicles with air conditioning, install the air conditioning compressor bracket (1). 10. Install the 4 air conditioning compressor bracket bolts (2) and tighten to 22 N·m (16 lb ft) .            11. For vehicles with air conditioning, install the air conditioning compressor (2). 12. Install the 3 air conditioning compressor bolts (1) and tighten to 22 N·m (16 lb ft) . 13. For vehicles with air conditioning, install the generator and the air conditioning compressor belt. Refer to Generator and Air Conditioning Compressor Belt Replacement . 14. Install the catalytic converter. Refer to Catalytic Converter Replacement . 15. Install the engine sight shield. Refer to Engine Sight Shield Replacement . 16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . 17. Fill the engine with engine oil. Refer to Engine Mechanical Specifications . 18. Close the hood.

11 Engine