Vauxhall Workshop Service and Repair Manuals

Exhaust Manifold, Replace (Z 17 DTH, with Air Conditioning, LHD)

  Remove

4.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt

6.   Remove air intake hose (1)

7.   Loosen air intake pipe (1) •   Unclip wiring harness •   Unscrew 2 bolts •   Remove engine vent hose

8.   Detach cooling module wiring harness •   Draw 2 series fuses (1) •   Remove relay holder •   Detach ground cable

15.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

22.   Loosen cooling module bracket •   Unscrew 2 bolts (1) •   Loosen 2 bolts (2)

24.   Detach connection hose (1) from turbocharger to charge air pipe •   Release clamp

25.   Remove air intake pipe (1) •   Release clamp

26.   Detach coolant hose, coolant connection (1) •   Release clamp Note:   Set coolant hose to one side

27.   Detach 2x vacuum line (3) •   Unscrew nut 28.   Detach oil dipstick guide tube •   Unscrew 4 bolts 29.   Remove ribbed V-belt 30.   Release alternator •   Disconnect wiring harness plug (1) •   Detach wiring harness – Unscrew nut (2) •   Remove nut •   Remove bolt Note:   Hinge alternator forwards 31.   Remove heat shield •   Unscrew 3 bolts 32.   Detach vacuum pump oil feed line (4) •   Unscrew banjo bolt

34.   Detach front exhaust pipe Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured to prevent it from sagging uncontrollably. The exhaust gas system piece with the flex pipe inside it can be fastened to the vehicle underbody with suitable materials such as wire. 2nd mechanic is required •   Unscrew 3x nut (1) 35.   Attach exhaust system •   Attach retaining rubber (5x) •   Tether exhaust system laterally Note:   Second person required

36.   Detach pre-catalytic converter (1) •   Unscrew 5 bolts

38.   Detach connection hose (1) from intercooler to intake pipe •   Release clamp

39.   Detach EGR cooler (1) •   Release 2 clamps (arrows) •   Unscrew 5 bolts •   Remove 2 gaskets

42.   Detach exhaust manifold heat shield •   Remove 4 bolts (1)

43.   Remove exhaust manifold with turbocharger •   Detach turbocharger oil feed line (1) – Unscrew banjo bolt •   Detach turbocharger oil return line (3) – Release clamp •   Detach wastegate unit vacuum line (2) •   Unscrew 2 bolts •   Unscrew 7x nuts •   Remove 2 gaskets

44.   Remove turbocharger (1) •   Unscrew 3 nuts •   Remove gasket.

  Install

62.   Install ribbed V-belt Note:   Observe running direction and installation position •   Release tension from ribbed V-belt tensioner (1) – I Ribbed V-belt without AC – II Ribbed V-belt with AC