Vauxhall Workshop Service and Repair Manuals

J456500 Oil Pan – Upper Part, Remove and Install (Y 17 DTL, without AC, LHD)

1. Open bonnet

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. Disconnect battery

• Detach ground cable

3. Remove oil filter element

• Place collecting basin underneath.
• Unscrew oil filter housing cover (1)

4. Remove oil dipstick guide tube

• Unscrew upper bolt

5. Raise vehicle

6. Remove ribbed V-belt cover Remove 3 bolts (1) Remove clip (arrow).

7. Drain engine oil

• Place collecting basin underneath.
• Remove drain bolt

8. Install drain bolt

• Replace seal ring
• Tighten bolt (78.4 Nm / 57.9 lbf. ft.)

9. Detach exhaust system

Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension.

For this purpose, the exhaust system portion including the flexpipe may be fastened to the vehicle underbody using suitable means, e.g. wire.

Caution!

Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can already cause damage and subsequent complete failure of the flexpipe.

• Detach rear muffler
• Release clamp
• Remove from rubber dampers
• Detach front exhaust pipe
• Remove 2 nuts

10. Remove exhaust system

• Remove exhaust system
• Remove from 2 damping rings
• Note! 2nd mechanic

11. Remove oil dipstick guide tube

• Remove 2 bolts

12. Detach lower part of oil pan Remove 15 bolts Detach with KM-J-37228

13. Detach upper part of oil pan Remove 14 bolts Note! Note dissimilar bolt lengths Remove 3 bolts (1) Remove 2 nuts Note! Use wide spatulas

14. Remove oil dipstick guide tube

15. Clean sealing surfaces

• Cylinder block, upper part of oil pan, lower part of oil pan

16. Install upper part of oil pan

• Apply sealing compound (grey)
• Caution! The application of silicone sealing compound (grey) and installation of lower part of oil pan including torque test must be performed within 10 minutes!
• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
• Tighten nuts (9.8 Nm / 7.2 lbf. ft.)
• Bolts (M10) (40 Nm / 29.5 lbf. ft.)

17. Attach lower part of oil pan

• Apply sealing compound (grey)
• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

18. Insert front exhaust pipe

• Into isolator rings
• Note! 2. mechanic

19. Fasten front exhaust pipe

• Replace gasket, nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)

20. Insert rear muffler

• Note! 2. mechanic

21. Fasten rear muffler

22. Attach ribbed V-belt cover

• Tighten bolts
• Install clip

23. Lower vehicle

24. Insert oil dipstick guide tube

• Replace seal ring

25. Raise vehicle

26. Install oil dipstick guide tube

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

27. Lower vehicle

28. Install oil dipstick guide tube

• Tighten upper bolt

29. Install oil filter element

• Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)
• Replace seal ring

30. Connect battery

31. Calibrate steering angle sensor

• Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

32. Top up engine oil

• Observe specified engine oil quantity
• Start engine and allow to run until oil pressure telltale extinguishes.
• Check engine oil level, if necessary correct.

33. Program volatile memories

34. Close bonnet