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Exhaust Camshaft Replacement > < Turbocharger Oil Return Pipe Replacement - 2.0L Diesel LBS and LBX

Astra J

Oil Pan Replacement

Special Tools

EN-37228   Separation Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
4. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
5. Remove the front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement .
6. Remove the front wheel drive intermediate shaft bracket. Refer to Front Wheel Drive Intermediate Shaft Bracket Replacement .
7. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .

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8. Disconnect the engine oil level sensor wiring harness plug (1).

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9. Remove the positive crankcase ventilation tube bolt (1) and hang the tube aside.
10. Remove the transmission bolt (3).

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11. Remove the 2 catalytic converter brace bracket bolts (1).
12. Remove the transmission bolt (2).

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Note:  Mark the positions of the oil pan bolts, because of different length.

Note:  Use a suitable tool.

Note:  Be carefully DO NOT damage the oil pan or the oil pan sealing surface.
13. Remove the 12 bolts (1).
14. Turn the engine to get access to the remaining 2 oil pan bolts through the opening in the flywheel.
15. Remove the oil sump (2) by using the EN-37228   separating tool .

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16. Remove the oil pump sealing (2) from the oil pump (1).
17. Disassemble the oil pan. Refer to Oil Pan Disassemble .

Installation Procedure

1. Assemble the oil pan. Refer to Oil Pan Assemble .

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2. Install a NEW oil pump sealing (2) to the oil pump (1).

Note:  Ensure that the oil pan sealing surfaces are clear of oil, grease and oil gasket material.
3. Clean the sealing surface from oil pump suction pipe (3).
4. Clean the oil pan sealing surface.

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Note:  DO NOT coat sealant on the oil sump bolt holes, it could damage the oil sump bolt threads or the engine block.

Note:  Refer to electronic parts catalogue to find a suitable sealing compound.
5. Coat the oil pan sealing surface with suitable sealing compound. The thickness of the sealing bead should be 2 mm (0.0787 in) .

Note:  The installation procedure should be done in 10 minutes.
6. Install the oil pan (2).

Caution: Refer to Fastener Caution .
7. Install the 10 M8 bolts and tighten to 25 N·m (18 lb ft) .
8. Install the 4 M6 bolts and tighten to 9 N·m (80 lb in) .

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9. Install the 2 catalytic converter brace bracket bolts (1) and tighten to 20 N·m (15 lb ft) .
10. Install the transmission bolt (2) and tighten to 40 N·m (30 lb ft) .

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11. Install a NEW seal ring (2) to the positive crankcase ventilation tube.
12. Install the positive crankcase ventilation tube bolt (1) and tighten to 9 N·m (80 lb in) .
13. Install the transmission bolt (3) and tighten to 40 N·m (30 lb ft) .

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14. Connect the engine oil level sensor wiring harness plug (1).
15. Install the front wheel drive intermediate shaft bracket. Refer to Front Wheel Drive Intermediate Shaft Bracket Replacement .
16. Install the front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement .
17. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
18. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
19. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
20. Refill the engine oil. Refer to Engine Mechanical Specifications .
21. Close the hood.

Exhaust Camshaft Replacement > < Turbocharger Oil Return Pipe Replacement - 2.0L Diesel LBS and LBX