Vauxhall Workshop Service and Repair Manuals

Exhaust Manifold, Remove and Install  

  Remove, Disconnect   

Remove fan motor - see operation "Fan motor Remove and Install". Remove the air intake hose bewteen the turbocharger and intake manifold and remove the charge air pipe holder from the cylinder head.   Remove the coolant hose from the radiator - collect the coolant. Remove the charge air pipe between the charge air cooler, upper coolant pipe and heat protection plate form the exhaust manifold. Remove the fixing screws (1) of the heat protection plate of the turbo charger. Remove the heat protection plate.

  Remove, Disconnect   

Exhaust pipe from turbocharger connection.   Detach oil feed line (1) from cylinder block and oil return pipe (2). Collect emerging engine oil.   Remove turbocharger support fastening bolt (3). Detach coolant lines from turbocharger. Collect emerging coolant.

  Remove, Disconnect   

Remove exhaust manifold fastening bolts and fastening nuts (1). Remove exhaust manifold (2) complete with turbocharger (3). Remove exhaust manifold gasket. Clean sealing surfaces and remove gasket residue.     Install, Connect    Fit the exhaust manifold (2) with turbocharger (3) and fit a new cylinder head gasket - tightening torque 24 Nm. Fit turbocharger support to cylinder block - tightening torque 51 Nm. Fit the exhaust pipe with a new seal to the turbocharger support - tightening torque 67 Nm.   Install lower coolant hose on radiator. Install oil return pipe.   Fit the oil feed line with a new seal to the cylinder block and the coolant pipes to the turbocharger. Fit the heat protection plate to the exhaust manifold and turbocharger. Install the upper coolant pipe, charge air pipe holder to the turbocharrger and charge air cooler. Fit the air intake hose to the turbocharger and intake manifold. Install the fan motor - see operation "Fan motor Remove and Install".   Top up cooling system - see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check For Leaks ". Check engine oil level, correct if necessary.