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Vauxhall Workshop Service and Repair Manuals

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Replacing exhaust manifold > < Removing and installing exhaust manifold with turbocharger

Astra H

Exhaust Manifold, Replace (from MY 2005.5)

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Raise vehicle by its full height
4.   For vehicles with air conditioning: Remove lower engine compartment cover and/or right engine splash guard
5.   Vehicles with air conditioning: Detach ribbed V-belt
•   Apply tension to tensioner anti-clockwise in the direction of the arrow at the cast projection
•   Insert KM-955-2 (1)
•   Relieve tension on ribbed V-belt tensioner
Object Number: 2410376 Size: DEFAULT


6.   Vehicles with air conditioning: Remove compressor
Note:   Air conditioning remains sealed
•   Unscrew 3x bolts (1)
Object Number: 2410407 Size: DEFAULT


7.   Disconnect wiring harness plug of catalytic converter control oxygen sensor
8.   Detach front exhaust pipe from catalytic converter
•   Unscrew 3x nut
9.   Detach exhaust system
•   Detach 2x damper rings
•   Suspend exhaust gas system from underbody at side
Object Number: 2410631 Size: DEFAULT


10.   Detach catalytic converter from bracket
Note:   During MY 2006 a new catalytic converter bracket will be used in protection (possibility 2) - the previous torque values also apply to the new brackets
11.   Option 1:
•   Unscrew 2x bolts (1)
Object Number: 7360876 Size: DEFAULT


12.   Option 2:
•   Unscrew 2x bolts (1)
Object Number: 10677770 Size: DEFAULT


13.   Lower vehicle by its full height
14.   Remove mixture regulator oxygen sensor (1)
•   Disconnect wiring harness connector (3)
•   Unclip wiring harness (2) from bracket
•   Unscrew oxygen sensor with KM-6170
Object Number: 9008151 Size: DEFAULT


15.   Remove 2x engine transport shackle (1)
•   Remove from cylinder head
– Unscrew 2x bolts
– Take out wiring harness bracket of oxygen sensor, mixture regulator
Object Number: 9008152 Size: DEFAULT


16.   Detach 2x coolant hoses from fan housing
•   Unclip 2x from bracket
17.   Place collecting pan underneath.
Object Number: 7360880 Size: DEFAULT

18.   Remove oil dipstick guide tube (2)
•   Detach from catalytic converter
– Unscrew bolt (3)
19.   Remove exhaust manifold
•   Unscrew 9x nuts (1)
•   Take out exhaust manifold upwards

20.   Clean sealing surface

  Install

21.   Install exhaust manifold
•   Use new gasket
– Apply assembly paste to stud bolts
•   Insert exhaust manifold from above
•   Screw in 9x new nut
22.   Raise vehicle by its full height
23.   Attach catalytic converter to bracket
•   Tighten 2x bolt 8 Nm
24.   Attach exhaust system
•   Use new gasket
•   Detach exhaust gas system from underbody at side
•   Attach 2x damper rings
25.   Fasten front exhaust pipe to catalytic converter
•   Tighten 3x new nut 20 Nm
– Apply assembly paste
26.   Connect wiring harness plug for catalytic converter control oxygen sensor
27.   In vehicles with air conditioning: attach compressor
•   Tighten 3x bolt 20 Nm
28.   Vehicles with air conditioning: Attach ribbed V-belt
•   Position ribbed V-belt
•   Apply tension to tensioner anti-clockwise in the direction of the arrow at the cast projection
•   Remove KM-955-2
29.   For vehicles with air conditioning: Install lower engine compartment cover and/or right engine splash guard
30.   Lower vehicle by its full height
31.   Fasten exhaust manifold
•   Tighten 9x nut 20 Nm (two passes)
– Tighten, working from inside to outside
32.   Attach 2x coolant hoses to fan housing
•   Clip 2x in bracket
33.   Install 2x engine transport shackle
•   Attach to cylinder head
– Insert wiring harness bracket of oxygen sensor mixture regulator
– Tighten 2x bolt 20 Nm
34.   Install dipstick guide tube
•   Replace 2x seal rings
•   Attach to catalytic converter
– Tighten bolt 8 Nm
35.   Install oxygen sensor mixture regulator
•   Coat thread with assembly paste
•   Oxygen sensor with 40 Nm
•   Fix wiring harness plug
•   Clip wiring harness into bracket
36.   Connect battery
•   Attach earth connection to earth terminal
– Tighten nut
37.   Check and correct engine oil level
38.   Program volatile memories
39.   Close bonnet

Replacing exhaust manifold > < Removing and installing exhaust manifold with turbocharger