vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Exhaust manifold with turbocharger, remove and install (with automatic transmission) > < Replace intake manifold

Astra H

Exhaust manifold with turbocharger, remove and install (with manual transmission)

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach ground connection from ground terminal
– Slacken nut
3.   Remove engine cover
4.   Remove air cleaner housing
5.   Detach coolant compensation tank cover
6.   Raise vehicle by its full height
7.   Detach the lower engine cover and right engine splash guard
8.   Place collecting basin underneath.
9.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


10.   Detach front exhaust pipe with middle silencer
•   Detach from catalytic converter
– Unscrew 3x nuts (1)
•   from oil pan
– Unscrew 2x nuts (2)
11.   Remove from exhaust pipe with middle silencer
Note:   Use a second person
•   Detach 4x damper rings
Important:   Prevent exhaust system from sagging in an uncontrolled manner. To do this, exhaust system with flexible pipe inside can be secured to underbody of vehicle using suitable material such as wire. Even flexible tube bending of 5 - 10 degrees from intended installation position can cause damage that may result in total failure of the flexible tube.
•   Suspend exhaust gas system from underbody at side
Object Number: 7360950 Size: DEFAULT


12.   Detach vacuum line (2) from oil dipstick guide tube (1)
•   Unclip 2x clips
13.   Detach oil dipstick guide tube from oil pan
•   Unscrew bolt (arrow)
Object Number: 7360944 Size: DEFAULT


14.   Disconnect air intake pipe (1) from turbocharger
•   Release clamp
Object Number: 7360945 Size: DEFAULT


15.   Undo turbocharger heat shield (1)
•   Unscrew 2x nuts (2)
•   Unscrew bolt (3)
Object Number: 7360951 Size: DEFAULT


16.   Lower vehicle by its full height
17.   Detach vacuum line
•   Unscrew 2x bolts (arrows)
•   Detach 2x hose from vacuum line
Object Number: 2408150 Size: DEFAULT


18.   Remove turbocharger charge air hose (1) from intercooler
•   Undo 2 clamps
Object Number: 7360935 Size: DEFAULT


19.   Remove engine vent hose from cylinder head cover
•   Release clamp (1)
Object Number: 3446023 Size: DEFAULT


20.   Remove air intake manifold (1)
•   Unscrew bolt (2)
Object Number: 8231077 Size: DEFAULT


21.   Remove oil dipstick guide tube (2)
•   Remove oil dipstick (1)
•   Unscrew bolt (3)
Object Number: 7360949 Size: DEFAULT


22.   Remove coolant pipe assembly (1)
•   Disconnect wiring harness plug of catalytic converter temperature sensor (2)
•   Unscrew 6x bolts
•   Detach 4x hose from coolant pipe assembly
– Undo 4x clamps
Object Number: 8231068 Size: DEFAULT


23.   Remove exhaust gas recirculation metal tube (1)
•   Unscrew 2x bolts
•   Release clamp
Object Number: 3446025 Size: DEFAULT


24.   Remove turbocharger heat shield (1)
•   Unscrew 2x bolts (3)
•   Unscrew nut (2)
Object Number: 7360954 Size: DEFAULT


25.   Detach turbocharger oil feed line (1) from turbocharger
•   Unscrew banjo bolt (2)
•   Remove 2x gaskets
Object Number: 7360955 Size: DEFAULT


26.   Undo catalytic converter fastening clamp (2)
•   Slacken nut
27.   Undo exhaust manifold with turbocharger (1)
•   Unscrew 7x nuts
Note:   One nut is used as retainer and is not unscrewed until removal takes place
Object Number: 7360956 Size: DEFAULT


28.   Raise vehicle by its full height
29.   Disconnect turbocharger vacuum hose (1)
•   from turbocharger vacuum hose
Object Number: 7360958 Size: DEFAULT


30.   Remove catalytic converter
•   Disconnect catalytic converter temperature sensor wiring harness plug
•   Detach catalytic converter bracket (2)
– Unscrew 2x bolts
– Unscrew nut
•   Remove clamp (1)
Object Number: 7360957 Size: DEFAULT


31.   Detach turbocharger oil feed line (1) from cylinder block
•   Unscrew banjo bolt (2)
•   Remove 2x gaskets
Object Number: 3446027 Size: DEFAULT


32.   Detach turbocharger oil feed line (1)
•   Unscrew 4x bolts
•   Remove 2x gaskets
Object Number: 3446026 Size: DEFAULT


33.   Remove exhaust manifold with turbocharger (1)
•   Unscrew nut
Note:   Twist exhaust manifold with turbocharger and remove from below
Object Number: 3446066 Size: DEFAULT


34.   Clean sealing surfaces.

  Install

35.   Insert exhaust manifold with turbocharger
Note:   Fill 0.4 ml clean engine oil into the aperture of the oil feed line
•   Replace seal
•   Insert exhaust manifold from below
•   Screw in new nut
Note:   Nut is used to secure exhaust manifold and is tightened later
36.   Lower vehicle by its full height
37.   Attach exhaust manifold at top
•   Tighten 8x new nut 25 Nm
38.   Raise vehicle by its full height
39.   Install turbocharger oil return line
•   Insert 2x new gaskets
•   Tighten 2x bolt on turbocharger 9 Nm
•   Tighten 2x bolt on cylinder block 25 Nm
40.   Attach oil feed line to cylinder block
•   Insert 2x new gaskets
Note:   Oil feed line must sit in guide at turbocharger
•   Tighten banjo bolt 15 Nm
41.   Install catalytic converter
•   Use new seal
•   Insert clamping sleeve
•   Attach catalytic converter bracket
– Tighten 2x bolts
•   Tighten nut
•   Connect catalytic converter temperature sensor wiring harness plug
42.   Attach front exhaust pipe with middle silencer
Note:   Use a second person
•   Suspend exhaust system from underbody
Important:   Prevent exhaust system from sagging in an uncontrolled manner. Even flexible tube bending of 5 - 10 degrees from intended installation position can cause damage that may result in total failure of the flexible tube.
•   Attach 4x damper rings
43.   Attach front exhaust pipe with middle silencer
•   Attach to catalytic converter
– Tighten 3x new nut 20 Nm
•   To oil pan
– Tighten 2x new nuts
44.   Connect turbocharger vacuum hose
45.   Renew oil dipstick guide tube gasket in oil pan
46.   Lower vehicle by its full height
47.   Attach oil feed line to turbocharger
•   Insert 2x new gaskets
•   Tighten banjo bolt 15 Nm
48.   Clean 2x threads
49.   Install turbocharger heat shield
•   Tighten 2x bolt 9 Nm
•   Tighten nut 9 Nm
50.   Install exhaust gas recirculation metal tube
•   Insert 2x new gaskets
•   Tighten 2x bolt 25 Nm
•   Tighten clamp 3.5 Nm
51.   Install coolant pipe assembly
•   Replace seal
•   Tighten 6x bolt
•   Connect catalytic converter temperature sensor wiring harness plug
•   Attach 4x hose to coolant pipe assembly
– Attach 4x clamps
52.   Fit turbocharger charge air pipe to intercooler
•   Tighten 2x clamp 3.5 Nm
53.   Install dipstick guide tube
•   Insert in oil pan
•   Attach to coolant pipe
•   Tighten bolt 9 Nm
•   Insert oil dipstick
54.   Install air intake pipe.
•   Tighten bolt 9 Nm
55.   Raise vehicle by its full height
56.   Attach air intake pipe to turbocharger
Important:   Follow specified installation order
•   Put seal on turbocharger port
•   Fit air intake manifold pipe
– Tighten clamp 3.5 Nm
57.   Attach turbocharger heat shield
•   Tighten bolt 9 Nm
•   Tighten 2x nut 9 Nm
58.   Attach oil dipstick guide tube to oil pan
•   Tighten bolt 9 Nm
59.   Clip 2x vacuum lines to oil dipstick guide tube
60.   Attach the lower engine cover and right engine splash guard
61.   Lower vehicle by its full height
62.   Attach vacuum line
•   Tighten 2x bolt 9 Nm
•   Attach 2x hose to vacuum line
63.   Attach engine vent hose to cylinder head cover
•   Fasten clamp
64.   Install air cleaner housing LUREF_1.gif
65.   Attach engine cover
66.   Fill with coolant and bleed LUREF_1.gif
67.   Connect battery
•   Attach ground connection to ground terminal
•   Tighten nut
68.   Program volatile memories
69.   Close bonnet

Exhaust manifold with turbocharger, remove and install (with automatic transmission) > < Replace intake manifold