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Gasket, Lower Part of Intake Manifold, Replace (Z 17 DTH, with AC, LHD) > < Intake Manifold Gasket, Replace

Corsa C

Exhaust Manifold Gasket, Replace

  Remove

1.   Open bonnet
Important:   On vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting. It must be recalibrated.
2.   Disconnect battery
3.   Drain coolant
•   Place collecting basin underneath.
•   Open drain bolt
Object Number: 2411059 Size: DEFAULT


4.   Remove charge air pipe (1)
•   Release 2x clamp
•   Unscrew 2x bolt (arrows)
•   Unclip wiring harness
•   Detach hose
Object Number: 2406298 Size: DEFAULT


5.   Detach turbocharger charge air pipe (3)
•   Release clamp
•   Open quick-release fitting
6.   Detach exhaust manifold heat shield (2)
•   Detach oil pressure switch wiring harness plug
•   Unscrew 3 nuts
•   Remove engine transport shackle
7.   Loosen heat exchanger coolant pipe (1)
•   Close coolant drain bolt
•   Place collecting basin underneath.
•   Unscrew 3 bolts
•   Release clamp
8.   Remove oil feed line (4)
•   Place collecting basin underneath.
•   Unscrew 2 banjo bolts
Object Number: 2406310 Size: DEFAULT


9.   Remove oil filter housing/heat exchanger housing (1)
•   Disconnect lower radiator hose
– Release clamp
•   Unscrew 4 bolts
Object Number: 2406311 Size: DEFAULT


10.   Loosen catalytic converter (1)
•   From turbocharger
•   Open retaining plate (2)
•   Unscrew 3 bolts
Object Number: 2406312 Size: DEFAULT


11.   Raise vehicle
Important:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.
12.   Remove exhaust system
•   Release clamp
13.   Disconnect catalytic converter
•   Remove bolt
•   Remove catalytic converter downwards
14.   Release turbocharger oil return line (2)
•   Unscrew 2 bolts
– From cylinder block
15.   Lower vehicle
16.   Remove exhaust manifold with turbocharger (1)
•   Unscrew 10x nut
Object Number: 2406313 Size: DEFAULT


17.   Cleaning work
•   Cylinder head

  Install

18.   Install turbocharger with exhaust manifold
•   Replace gasket
•   Tighten 10 new nuts 15 Nm + 30°
19.   Raise vehicle
20.   Attach turbocharger oil return line
•   Tighten 2 bolts 9 Nm
– At cylinder block
21.   Fit catalytic converter
•   Bolt in bolt
22.   Lower vehicle
23.   Attach catalytic converter
•   To turbocharger
•   Replace gasket
•   Tighten 3x bolts 30 Nm
•   Fasten 3 bolts
– Replace retaining plate
24.   Attach exhaust manifold heat shield
•   Replace 3x nut
•   Tighten 3 new nuts 9 Nm
•   Attach engine transport shackle.
•   Connect oil pressure switch wiring harness plug
25.   Cleaning work
•   At cylinder block
26.   Install oil filter housing
•   Replace gasket
•   Tighten 4 bolts 9 Nm
•   Connect lower radiator hose
– Fasten clamp
27.   Install turbocharger oil feed line
•   Replace 4x seal ring
•   Tighten 2 banjo bolts 12 Nm
28.   Attach heat exchanger coolant pipe
•   Replace gasket
•   Tighten 3 bolts 9 Nm
29.   Install charge air pipe
•   Attach 2 clamps 3.5 Nm
•   Tighten 2 bolts
•   Attach wiring harness
•   Attach hose
30.   Attach turbocharger charge air hose
•   Fasten clamp
•   Close quick-release fitting
31.   Raise vehicle
32.   Fasten catalytic converter
•   Tighten bolt 25 Nm
33.   Attach exhaust system
•   Fasten clamp
34.   Lower vehicle
35.   Check engine oil level, if necessary correct.
•   Observe specified engine oil quantity
36.   Connect battery
37.   Top up coolant
38.   Program volatile memory
39.   Close bonnet

Gasket, Lower Part of Intake Manifold, Replace (Z 17 DTH, with AC, LHD) > < Intake Manifold Gasket, Replace