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Vauxhall Workshop Service and Repair Manuals

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Exhaust System Replacement - 1.6L LDE, LLU and 2H0 > < Exhaust Manifold Replacement - 2.0L Diesel LBQ, LBR, LBS and LBX

Astra J

Exhaust Rear Muffler Replacement (without 1.6L LLU)

Special Tools

CH-6614   Chain-Type Pipe Cutter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Exhaust Service Warning .

Warning:  Refer to Protective Goggles and Glove Warning .

Caution: Refer to Exhaust Flexible Pipe Bending Caution .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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2. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler (4).
3. Remove the exhaust rear muffler end pipe bracket bolt (1) from the exhaust rear muffler end pipe bracket (2)
4. Remove the exhaust rear muffler end pipe bracket (2).
5. Place the exhaust system onto the rear axle.

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6. Note the dent marks (1) around the exhaust pipe, if available.

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7. If no markings are available, measure and mark the cut position as shown in the graphic.

Note:  Use a suitable flat steel bar (2) or equivalent tool to measure the cut position I and II with a rule (1).

Note:  A second technician is required.
  •  Cut position for 1.4L LDD; I= 143 mm; II= 142 mm
  •  Cut position for 1.4L LUJ; I= 141 mm; II= 145 mm
  •  Cut position for 1.6L LDE; I= 140 mm; II= 144 mm
  •  Cut position for 1.3L Diesel; I= 139 mm; II= 144 mm
  •  Cut position for 1.7L Diesel; I= 140 mm; II= 147 mm
  •  Cut position for 2.0L Diesel; I= 142 mm; II= 149 mm

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8. Support the intermediate pipe.
9. Cut the exhaust rear silencer (4) with CH-6614   cutter (2) at the marked position (3).
10. Remove the exhaust rear muffler end pipe.
11. Cut the exhaust rear muffler (4) at the marked position (1).
12. Remove the exhaust rear muffler.

Installation Procedure

1. In case of reuse of the exhaust parts, check the exhaust pipes at the separating sets for the following conditions:
  •  Roundness of the exhaust pipe, any deformation in the area of the double-clamp must be eliminated.
  •  Burrs inside and outside the exhaust pipe at the cutting edge, use a rasp to eliminate.
  •  Rust at the exhaust pipe outside, use sandpaper to eliminate.

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Note:  A second technician is required.
2. Install the exhaust rear muffler (6) at the 2 exhaust rear muffler hanger insulators (5).
3. Install the exhaust pipe clamp (1) and loosely tighten.
4. Install the exhaust rear muffler end pipe.
5. Install the exhaust rear muffler end pipe bracket (3) to the exhaust rear muffler end pipe.

Caution: Refer to Fastener Caution .
6. Install the exhaust rear muffler end pipe bracket bolt (4) to the exhaust rear muffler end pipe bracket (3) and tighten to 22 N·m (16 lb ft) .
7. Install the exhaust pipe clamp (2) and loosely tighten.
8. Position the exhaust rear muffler.
9. Tighten the exhaust pipe clamps (1) to 30 N·m (22 lb ft) .
10. Position the exhaust rear muffler end pipe.
11. Tighten the exhaust pipe clamp (2) to 30 N·m (22 lb ft) .
12. Lower the vehicle.

Exhaust System Replacement - 1.6L LDE, LLU and 2H0 > < Exhaust Manifold Replacement - 2.0L Diesel LBQ, LBR, LBS and LBX