Vauxhall Workshop Service and Repair Manuals

Bypass Connection Flange on Cylinder Head, Remove and Install  

  Remove, Disconnect   

Release ribbed V-belt and remove from alternator pulley - see operation "Ribbed V-belt, Remove and Install".   Detach alternator shackle (1) from alternator, from lower part of intake manifold and from bypass connection flange. Swing alternator to rear.

Depressurise cooling system by opening closure cap on coolant compensation tank.   Drain coolant. For this purpose, detach lower coolant hose from radiator and collect emerging coolant.   Remove coolant hose from bypass connection flange.   Remove bypass connection flange from cylinder head (arrows, see illus.).

  Clean   

Remove gasket remnants and clean sealing surfaces.  

  Install, Connect   

Attach bypass connection flange with new gasket to cylinder head (arrows) - 25 Nm / 18 lbf. ft.   Attach coolant hoses to radiator and bypass connection flange.

Attach alternator shackle (1, see illus.) to alternator - 20 Nm / 15 lbf. ft., to lower part of intake manifold - 20 Nm / 15 lbf. ft. and to bypass connection flange - 20 Nm / 15 lbf. ft.   Install ribbed V-belt - see operation "Ribbed V-belt, Remove and Install".   Top up cooling system - see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".